DBR 2x18MW

OC No.
Total sheets
C030 Document No. PP 030 M B01 0 100
DESIGN BASIS REPORT
(MECHANICAL)
For
1 Revised as per FIL comments SA SA BB
Approval
For - - - -
0 1.12.05 First Issue
Approval SA SA - - - - BB
Mech
Appd
Appd
Civil
Elec
C&I
Ckd
Ppd
Ppd
QA
PM
Rev Date Description of Revisions Status

DEC THERMAX LTD.
OWNER JK CEMENT LTD LIMITED
OWNER’S
ENGINEER FICHTNER CONSULTING ENGINEERS (I) PVT. LTD
PROJECT 2 x 18 MW COAL BASED CAPTIVE POWER PLANT
COGEN DIVISION
THERMAX LIMITED
PUNE
Format No.:CGN-E-F-03, Sht 1, Rev 1 dt. 02/Mar/2001

COGEN DIVISION THERMAX LIMITED
Project Document Title Doc. No. Rev. Sheet
2 x 18 MW CPP
JK Cement Ltd , Sirohi, Design Basis Report
PP 030 M B01 0 1 2
Rajasthan (Mechanical)
INDEX
INDEX ....................................................................................................................................................................2
1. INTRODUCTION .........................................................................................................................................5
2. UNITS OF MEASUREMENT & ABBREVIATIONS...............................................................................5

2.1. UNITS OF MEASUREMENT ........................................................................................................................5
2.2. ABBREVIATIONS .......................................................................................................................................5
3. CODES & STANDARDS..............................................................................................................................6
4. POWER PLANT CONFIGURATION........................................................................................................8

4.1. PLANT CONFIGURATION ...........................................................................................................................8
4.2. PLANT STARTUP, OPERATION AND CONTROL PHILOSOPHY ......................................................................9
4.3. SITE CONDITIONS .....................................................................................................................................9
5. POWER PLANT LAYOUT .......................................................................................................................11
5.1. POWER BLOCK AREA .............................................................................................................................11
5.2. BOILER AREA .........................................................................................................................................13
5.3. AIR COOLED CONDENSER AREA ...............................................................................................................14
5.4. COOLING TOWER AREA ..........................................................................................................................14
5.5. FUEL AREA .............................................................................................................................................14
5.6. WATER TREATMENT AREA.....................................................................................................................14
5.7. MISCELLANEOUS ....................................................................................................................................15
6. STEAM TURBINE......................................................................................................................................15
6.1. GENERAL ................................................................................................................................................15
6.2. TURBINE .................................................................................................................................................15
6.3. GLAND STEAM SYSTEM ..........................................................................................................................16
6.4. TURBINE DRAIN SYSTEM ........................................................................................................................17
6.5. TURBINE LUBE OIL SYSTEM ...................................................................................................................17
6.6. TURNING GEAR ......................................................................................................................................19
6.7. MAIN STEAM STOP VALVES ...................................................................................................................19
6.8. MAIN TECHNICAL PARAMETERS OF EACH TURBINE .............................................................................20
7. BOILER AND AUXILIARIES ..................................................................................................................20
7.1. GENERAL ................................................................................................................................................20
7.2. BOILER PRESSURE PARTS .......................................................................................................................22
7.3. BOILER MOUNTINGS AND FITTINGS ........................................................................................................27
7.4. SOLID FUEL FIRING SYSTEM ...................................................................................................................28
7.5. AIR AND FLUE GAS SYSTEMS .................................................................................................................31
7.6. THE AIR HEATER WILL COMPRISE CARBON STEEL TUBES OF MATERIAL SPECIFICATION BS 6323. FEED
WATER SYSTEM .................................................................................................................................................36
7.7. BOILER STRUCTURES AND AUXILIARIES.................................................................................................40
7.8. REFRACTORY AND INSULATION ..............................................................................................................41
7.9. CHEMICAL DOSING SYSTEM ...................................................................................................................42
7.10. SAMPLING LINES AND SAMPLE COOLERS ...........................................................................................43
7.11. BLOW DOWN TANKS ..........................................................................................................................43
8. STEAM FEED WATER AND CONDENSATE SYSTEM......................................................................46
8.1. STEAM SYSTEM ......................................................................................................................................46
Format No.: CGN-E-F-03, Sht 2, Rev 1 dt. 02/Mar/2001

2 x 18 MW CPP
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8.2. FEED WATER SYSTEM ............................................................................................................................49

8.3. CONDENSATE SYSTEM ............................................................................................................................51
8.4. STEAM AND WATER CHEMISTRY ............................................................................................................57
9. PLANT WATER SYSTEM ........................................................................................................................58
9.1. PLANT WATER SYSTEM ...........................................................................................................................58
9.2. COOLING WATER SYSTEM ......................................................................................................................62
9.3. SERVICE & DRINKING WATER SYSTEM ..................................................................................................66
10. FUEL & LIME STONE HANDLING SYSTEM..................................................................................66
10.1. ANALYSIS OF COAL & COAL CONSUMPTION ......................................................................................66
11. CONSTITUENT ......................................................................................................................................70
11.1. SYSTEM SIZING...................................................................................................................................70
11.2. HSD SYSTEM .....................................................................................................................................73
11.3. SYSTEM DESCRIPTION ........................................................................................................................74
11.4. SYSTEM SIZING...................................................................................................................................76
12. COMPRESSED AIR SYSTEM..............................................................................................................77
12.1. PROCESS DESCRIPTION .......................................................................................................................77
12.2. SYSTEM SIZING...................................................................................................................................77
13. AIR CONDITIONING & VENTILATION SYSTEM.........................................................................82
13.1. SYSTEM DESCRIPTION ........................................................................................................................82
13.2. SYSTEM SIZING...................................................................................................................................85
14. EOT CRANE ...........................................................................................................................................89
14.1. DESCRIPTION ......................................................................................................................................89
14.2. EOT CRANE SIZING ............................................................................................................................89
15. FIRE PROTECTION SYSTEM ............................................................................................................90
15.1. PROCESS DESCRIPTION .......................................................................................................................90
15.2. SYSTEM SIZING CALCULATION ...........................................................................................................91
15.3. PUMP SIZING ......................................................................................................................................92
16. PIPING SYSTEM....................................................................................................................................92
16.1. POWER CYCLE PIPING ........................................................................................................................92
16.2. LOW PRESSURE UTILITY PIPING ..............................................................................................................93
16.3. COOLING WATER PIPING .........................................................................................................................93
16.4. DESIGN BASIS FOR PIPING .......................................................................................................................93
16.5. MAIN STEAM PIPING ...............................................................................................................................95
16.6. OTHER STEAM PIPELINES ........................................................................................................................96
16.7. BOILER FEEDWATER PIPING .....................................................................................................................96
16.8. CONDENSATE PIPING ...............................................................................................................................96
16.9. PIPING FOR RAW WATER, COOLING WATER .............................................................................................96
16.10. AIR PIPE LINE ......................................................................................................................................97
16.11. DM WATER PIPE LINE .........................................................................................................................97
16.12. EFFLUENT ...........................................................................................................................................97
16.13. SERVICE AND POTABLE WATER PIPE LINE ............................................................................................97
16.14. AUXILIARY COOLING WATER PIPING ...................................................................................................97
16.15. FIREWATER PIPING .............................................................................................................................97
16.16. VALVES ..............................................................................................................................................98
16.17. GENERAL GUIDELINES FOR PIPING ...................................................................................................100
17. ENVIRONMENTAL CONSIDERATION..........................................................................................101

2 x 18 MW CPP
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17.1. GASEOUS EMISSION ..........................................................................................................................101

17.2. LIQUID EFFLUENT.............................................................................................................................102
18. REFERENCE DRAWINGS & DOCUMENTS ..................................................................................104

2 x 18 MW CPP
PP 030 M B01 0 1 5
1. INTRODUCTION
This document aims at establishing the criteria for basic and detail engineering,
sizing and specifications of the Power Plant equipment, components, and piping for the 2 x
18 MW Captive Power Generation Plant at Sirohi, Rajasthan being set up by M/s. JK
Cement Ltd Limited (DEL).
The basic design inputs like Fuel analysis, Water analysis, Site conditions, etc. will
be spelt out elaborately in the contract document. They are included in this document in
the appropriate section for the purpose of clarity & completeness. It may be noted that
during the course of Engineering, as more details are worked out and complete, guaranteed
details of equipment are available from Vendors, some changes may have to be
accommodated without compromising the overall performance operability & reliability.
2. UNITS OF MEASUREMENT & ABBREVIATIONS

2.1. UNITS OF MEASUREMENT
Deg.C Degree Celsius

Kg/cm2 Kilograms per square Centimetre
Ksc Kilograms per square Centimetre
kV Kilo Volt
kW Kilo Watt
MLC Meters of Liquid Column
MW Mega Watt
MWC Meters of Water Column
No. Number
Nos. Numbers
TPH Tons Per Hour
2.2. ABBREVIATIONS
ACW Auxiliary Cooling Water System

AHP Ash Handling Plant
CEP Condensate Extraction Pump

2 x 18 MW CPP
PP 030 M B01 0 1 6
CHP Coal Handling Plant

CPP Captive Power Plant
CV Control Valve
DBR Design Basis Report
DM De-Mineralised
HP High Pressure
LP Low Pressure
MB Mixed Bed
MCW Main Cooling Water System (for Condenser)
MOC Material of Construction
MSL Mean Sea Level
PRDS Pressure reducing & Desuperheating Station
PRV Pressure reducing Valve
Re Reynolds Number
RL Reference Level
ACC Air Cooled Condenser
SAC Strong Acid Cation
SBA Strong Base Anion
SHP Superheated High Pressure
STG Steam Turbine Generator
TDH Total Dynamic Head
UF Ultra Filtration
BFP Boiler feed pump
3. CODES & STANDARDS

The design and construction of the various systems, equipment & components will
be in accordance with the relevant Indian and International Standards. This shall also be in
accordance with the applicable laws and regulations of the Central / State Government and
relevant Statutory bodies of the government. A summary of the codes and industry
standards acts & laws generally to be used in the design and construction is listed below;
• Indian Standards (IS)
• International Electrotechnique Commission (IEC)
• DIN Standards
• British Standards
• American Society of Mechanical Engineers (ASME)
• American Society of Testing and Materials (ASTM)

2 x 18 MW CPP
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• American Welding Society (AWS)
• American Water Works Association (AWWA)
• American National Standard Institute (ANSI)
• Heat Exchanger Institute (HEI)
• Manufacturer’s Standardisation Society (MSS)
• Hydraulic Institute (HI)
• Japanese Industrial Standards (JIS)
• Tariff Advisory Committee of India (TAC)
• National Fire Protection Association (NFPA)
• Occupational Safety and Health Administration (OSHA)
• Steel Structures Painting Council (SSPC)
• Tubular Exchanger Manufacturer & Association (TEMA)
• Indian Boiler Regulation (IBR) Act
• American Petroleum Institute (API) codes
• Indian Explosives Act
• Environment Protection Agency (EPA) codes
• Petroleum Act
• Oil Industry Safety Directorate (OISD)
If not mentioned otherwise, only the latest publication of the Codes & Standards
will be used. In case for certain system / equipment / component where no national /
international standard is available, general Good Engineering Practice will be followed. In
some specific cases, Manufacturer’s Standard may be adopted if found to be proven and
meets the requirement of high degree reliability.

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4. POWER PLANT CONFIGURATION

4.1. PLANT CONFIGURATION
The Captive power plant consists of the following;
Two (2) Boilers: Top supported fluidised bed combustion type, each generating 80 TPH at
89 kg/cm2 (a) pressure and 515°C temperature at main steam stop valve.
Two (2) STGs : Multi-stage, single flow, condensing type Steam Turbine Generator, each
with three bleeds for regenerative heating generating 18MW at 6.6 kV with an inlet steam at
85 kg/cm2(a), 510oC.
Air Cooled Condenser with air evacuation system, condensate extraction pumps, LP & HP
heater - one set for each STG.
One auxiliary cooling tower with 3 working cells (2 working + 1 standby) with cross flow
design and FRP construction.
Fuel & Ash Handling System.
Raw water, Pre-treatment & DM Water System
Air Compressor & Air Drying plant for Compressed air system.
Air conditioning &Ventilation System.
Fire Protection System.
All other associated equipment & auxiliaries as required for the operation of the plant.
The main fuel used for the boiler will be 70% petcoke + 30% imported coal (based
on heat value). The boiler is capable of firing following fuel combinations
(a) 70% Petroleum coke (Petcoke) & 30% Imported coal on heat value basis
with Lime stone dosing.
(b) 100% Imported coal
(c ) 100% Indian coal
The turbine exhaust steam will be condensed in an air cooled condenser provided
with each turbine. Condensate from the condenser hot well shall be pumped to the
common deaerator by the condensate extraction pumps. The condensate is pumped
through the inter/after condensers, Gland Steam Condenser and LP heater before reaching
the Deaerator.

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Make up water for the power cycle shall be Demineralised (DM) Water. Make-up
water will be added to the Deaerator.
Feed water to the Boilers shall be fed by three boilers feed pumps (3x100% where
100% corresponds to one Boiler's MCR requirement) which shall take the suction from the
Deaerator.
The boilers will be connected to a common RCC chimney, 93m height..
4.2. PLANT STARTUP
For the start-up of the captive power plant, the proposed bi-directional (2 no.
6.6kV/138 kV, 20 / 24 MVA) transformer will be utilized.
The operational sequence for start-up of the CPP using 1 no. 6.6kV/138 kV, 20 / 24
MVA transformers is as follows:
(a) Power will be made available from grid or existing (cement plant) DGs to 6.6 kV
CPP switchgear through 132 kV switchyard and bidirectional power
transformer.
(b) Once the 6.6 kV switchgear is energized, the CPP HT auxiliary loads will be
started as well as CPP LT auxiliary transformers will be energized.
(c) After starting the Boiler and TG auxiliaries, the generator will be synchronized at
6.6kV.
For details refer to Electrical and C&I design basis report.
4.3. SITE CONDITIONS
4.3.1. LOCATION:
•Sirohi , Rajasthan
•Site Elevation : 372M above MSL
4.3.2. AMBIENT CONDITIONS

•Minimum Ambient Temperature : 7°C
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(Average)
•Maximum Ambient Temperature : 46°C

(Average)
•Design ambient for electrical equipment : 50°C
•Design Relative Humidity : 60%
•Average rain fall per annum : 484 mm / year
•Basic wind speed : 47 m/s
•Design wet bulb temperature : 28 °C
4.3.3. SEISMIC DATA

• As per IS 1893, the area falls in Seismic Zone II.
4.3.4. SOIL DATA

• Soil investigation report will be the basis for the civil design.
4.3.5. POWER SUPPLY

• Export Voltage : 132 kV, 3 ph, 3 wire , 50 Hz
• For AC motors above 180 kW : 6600 V (±10%), 3 phase, 50 Hz ±5% earthed
• For AC motors upto 180 kW : 415 V (±10%), 3 phase, 50 Hz ±5%, solidly

earthed.
• Control Voltage for equipment, 6.6 : 110V DC
kV Switchboards, 6.6kV
Switchboards, 415V PCCs, 415V
MCCs
• MCC Contactor for motor feeder : 110V AC, 50 Hz feeders
• For lighting fixture and space heaters : 240 V ±10%, 1 phase, 50 Hz ±5%, solidly
earthed.
• For solid state controls and : 110 V AC, 1 ph, 2 wire, 50 Hz (UPS).
annunciation / local control panel:
• Construction power : 415 V (±10%), 3 ph., 4 wire, 50 Hz ±5%, AC

solidly earthed

2 x 18 MW CPP
PP 030 M B01 0 1 11
All equipment shall be suitable for continuous operation under the following power
supply condition;
• AC supply : ±10% V, ± 5% Hz, ± 10% V & Hz combined
• DC supply : ± 15% V
5. POWER PLANT LAYOUT

The following factors are considered in Developing the Plant Layout;
• Air cooled condenser located farthest from dust sources viz., coal handling plant, ash silos
and ESPs and cement plant.
• Space provided for the future 1 x 18MW Unit.
• Raw water reservoir located farthest from dust sources viz., cement plant and coal
handling plant.
• Adequate clearances and access around each equipment for routine inspection and
maintenance.
• Convenience of power evacuation.
• Logistics for road tanker movement.
The power plant is broadly classified into Power block area, Coal & Ash area,
water reservoir, DM Plant area, Air cooled condenser area and Boiler area.
5.1. POWER BLOCK AREA
The following areas, buildings, structures and equipment are located within the
power block;
5.1.1. POWER HOUSE:
The Power House will include:
Steam Turbine Generator & auxiliaries, LP & HP heaters located in the Steam
Turbine Hall.
The two- (2) nos. Steam turbine generators will be located in the turbine hall of 7
bays of 8 M each, totalling to 56 M span. The layout of the STG hall shall be designed
considering the following:
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1. Adequate space for maintenance of Steam Turbine and generator shall be provided.
2. The STG unloading and maintenance area has been provided on the turbine side.
3. The Turbogenerator (TG) deck elevation shall be selected based on:
9 Adequate vertical distance under the turbine exhasut flange to accommodate
the transition piece and exhasut duct.
9 Elevation of intermediate floor
4. The crane rails elevation of the turbine hall shall be selected based on turbine
height and crane clearance required above turbine.
5. The Lube Oil System will be located at an intermediate floor between the operating
floor & the Mezzanine floor.
6. The Deaerator will be mounted on the roof of the control building. The Deaerator
foundation design will take into consideration any possible vibration due to steam
chugging. The boiler feed pumps shall be located in the ground floor of the
Turbine Building.
7. A mezzanine floor would be provided to accommodate STG auxiliaries like Gland
Steam Condenser, HP & LP Heaters, etc.
8. Adequate number of staircases shall be provided for easy access to each floor and
as per fire protection norms of TAC.
9. The ventilation fans shall be located on top of the STG building control room. One
set of fans dedicated for the switchgear room and cable cellar and other set of fans
for the turbine hall.
Control & Switchgear room

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The main control room, electrical switchgear room, the cable spreader rooms,
battery rooms, UPS room, Air Conditioner room and office space shall be housed within
this bay of the Powerhouse.
The cable spreader room shall be provided on the ground floor below the
Switchgear and MCC room.
The electrical switchgear will be located in the control building at about 4.0 m
above the cable spreader room.
All MCCs except the Water, Fire MCC (which shall be kept in the Water
Treatment area) and the coal handling MCC (which will be located in the coal handling
MCC room) will be located in the Switchgear room.
The main control room will house the DCS and the electrical control panels. UPS
room will be located adjacent to the main control room. This will be located on the
operating floor adjacent to the TG unit on a false floor permitting easy cable layout.
Battery charger and battery room shall be located on the operating floor.
5.2. BOILER AREA
The boilers shall be provided with roof and side cladding down to the steam drum.
The feeding area (i.e. below the fuel bunkers upto the drag chain feeding floor
level) will be provided with side cladding. The entire outer casing for the boiler, auxiliaries
and piping shall be designed suitable for outdoor installation.
All Bunkers will have adequate rooftop covering with side cladding upto bunker
floor.
Distance between the boiler centrelines are maintained as 28.5 m. All fans
(FD/ID/PA) are suitably located to provide adequate access for maintenance of the same.
The boilers shall be connected to a common RCC chimney provided with necessary
aviation lighting, lightning-protection, sampling ports with platforms etc.

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5.3. AIR COOLED CONDENSER AREA Formatted: Bullets and Numbering
The air cooled condensers will be located near the turbine hall with the minimum
distance required for the bends for the exhaust duct. An effort will be made to combine the
steam exhaust duct collection pot with the condensate storage tank. Further details will be
provided after deliberating this aspect with the air cooled condenser vendors. Adequate
space will be provided along the sides of the air cooled condenser.
5.4. COOLING TOWER AREA
The cooling tower shall be of FRP construction. A fore bay shall be provided for
cooling water pumps suction. The dimension of cooling tower basin and the forebay shall
be selected to accommodate three(2W + 1 S) cells each of 250 m3/hr capacity. Cooling
water pumps shall be horizontal and located such that easy access and maintenance is
ensured. Each cell of the towers shall be provided with a drain sump.
Cooling water piping to the plant will be buried , wherever over ground piping
would cause obstruction or hindrance to man or vehicle movement.
5.5. FUEL AREA
The truck tippler and the grizzly hopper will be located away from the air cooled
condenser and switch yard. Adequate space will be provided around the emergency
hopper for fuel loading by means of dumpers in case truck tippler is not available
due to any maintenance.
The crusher house will house coal /limestone/Petcoke Primary screen and crushers.
The screen house will house the vibrating feeders and screens.
5.6. WATER TREATMENT AREA
5.6.1. WATER RESERVOIR
Raw water reservoir will be of open earthen bund construction with RCC/Geo
membrane lining to avoid seepage of water. The capacity of the reservoir will be 1000 m3
to cater to the water requirement of CPP and fire water requirement for CPP. All the
pumps (i.e. 2 numbers Raw Water transfer pumps and 3 numbers Fire Water Pumps) will
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draw suction from this sump. These pumps will be housed in Raw Water Cum Fire water
Pump house.
5.6.2. WATER TREATMENT AREA
Water Treatment Plant is located to the north of the Power Plant. The Water
Treatment Plant Control Room is located to the north-west of the water treatment plant.
5.7. MISCELLANEOUS
The interconnection pipe work between plant utilities and power block equipment
will be routed through pipe racks / sleepers and pipe trenches depending on the layout. The
Auxiliary Cooling water piping will be laid below ground and buried, wherever over
ground piping would cause obstruction or hindrance to man or vehicle movement.
6. STEAM TURBINE
6.1. GENERAL Deleted: ,
The Steam Turbine will be of horizontal, single casingimpulse-reaction with 11

impulse stages & 3 reaction stages with axial flow multistage construction, design
conforming to IEC-45/JIS/JEC.
The Turbine will be designed with three bleeds, for the regenerative heating
requirement in LP Heater, Deaerator and HP Heater.
The various components of the STG are described below.
6.2. TURBINE
The condensing Steam Turbine shall be designed as a single casing machine

connected to the generator. Live steam enters the turbine through the steam strainer and
Emergency stop valve. The inlet steam chamber shall have the governing valves bolted to
the front upper part of the casing. The position of the governing valves is governed by the
lifting bar, which in turn is governed by the hydraulic actuator placed on the front part of
governing valves chamber.

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The turbine casing shall be of single shell design. The diaphragms of the stages
shall be centred by key and side suspensions so that the concentricity is maintained during
all temperature states of the turbine. The bleeds shall be situated on the turbine casing
lower half.
The STG rotor shall be of one-piece forging. The root diameter of the governing
stage moving blade shall increase along the length of the casing from inlet to exhaust.
Moving blades of the initial stages shall normally be fixed to the rotor by "T" clamped
roots and moving blades of the last stage.
Rear bearing pedestal, which is a part of the exhaust casing, shall contain the rear
turbine journal bearing. The turbine shall be coupled with the high-speed shaft of the
gearbox by a flexible coupling and the low speed shaft of the gearbox shall be coupled
with the generator rotor by a rigid coupling.
6.3. GLAND STEAM SYSTEM
Shaft outer and interstage glands shall be of the contactless labyrinth type. The
labyrinth rings with the machined sealing collars and recesses shall be split in multiple
segments that would be pushed in the working position by the flat springs and by the steam
pressure. The stator labyrinth rings segments can be pushed away from the rotor in case of
accidental contact and the rubbing of rotating and stationary parts can be minimised. The
shaft shall have in the gland sections caulked sheet fins that together with the stator collars
form the small chambers of the labyrinth gland. The front outer gland shall be fed from a
pressure-control valve, which shall receive the steam from the Main steam line. The rear
outer gland seals during the operation permanently face the vacuum inside of the turbine
casing and must be therefore continuously fed by the steam. The feeding steam shall be
taken from the front gland leakage. The leakage steam from outer labyrinths shall go to the
Gland Steam Condenser (GSC). The gland sealing supply control valve shall be controlled
by a pressure transmitter located on gland steam supply header.
Last sections of both front and rear outer glands shall be slightly below atmospheric
pressure. The gland steam condenser shall keep the pressure in the last sections lower than

2 x 18 MW CPP
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atmospheric and to ensure that there is no leak of steam from the glands in the machine
room.
The condensate collected from the Gland steam Condenser shall be sent to the main
condenser and the non-condensable gases shall be vented to the atmosphere.
6.4. TURBINE DRAIN SYSTEM
During every start-up it shall be ensured that the drain valves provided on the
turbine casing , ESV casing , governor control valve and Extraction steam line are opened
to drain the entrapped condensate to avoid damage due to high-energy water accumulation
or ingress.
6.5. TURBINE LUBE OIL SYSTEM
6.5.1. OIL STORAGE TANKS
The turbine will have one (1) oil tank with a such that the contents are cycled not
more than 8 times per hour.. The oil tank will be provided with necessary level indicator,
inlet and outlet oil connections and exhaust fan to evacuate oil vapour from the tanks. Oil
tank is also provided with necessary connections for oil centrifuge.
6.5.2. OIL COOLERS
Two (2) oil coolers, each designed with adequate margin, horizontally mounted
will be provided with one (1) running and the other stand-by. The lube oil coolers shall be
interchangeable during service without interruption to oil flow. The oil cooler tube will be
of copper material. The shell and water boxes will be made out of carbon steel plates of
material specification conforming to IS-2062.
6.5.3. OIL PUMPS
6.5.3.1. Main Lube Oil Pump
The turbine will have a gear type, shaft driven main lube oil pump for supplying
lube oil to the turbine, gearbox and alternator bearings.

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6.5.3.2. Auxiliary Lube Oil Pump
The turbine will have a 1 x 100% gear type, AC motor driven, mounted on top of
oil reservoir, auxiliary lube oil pump designed as full duty oil pump so as to work as stand
by to main lube oil pump.
6.5.3.3. Emergency Oil Pump
The turbine will be provided with an Emergency oil pump (EOP) of gear type,
mounted on top of oil reservoir, driven by 110 V DC motor. It will cater to the needs of
bearings of turbine, gearbox and alternator in case of failure of AC motor driven Auxiliary
Lube oil pump. The EOP control shall be electronically fail safe type.
6.5.3.4. Overhead Tank
In the event of a Turbine trip when A/C power is not available, the emergency Oil
pump, driven by DC power will ensure that necessary lubrication oil is supplied to the
Turbine Bearings for safe Coast Down. In the unlikely event of non-availability of DC
power also, the oil pressure in the header may tend to go down. An overhead tank of
adequate capacity is provided for each Turbine for supplying oil to the bearing under such
events. The Oil from the tank will flow by gravity & will be initiated based on low header
pressure.
6.5.3.5. Main Control Oil Pump
The turbine will have a Positive displacement type main control oil pump,
mounted on base plate and driven by AC motor.
6.5.3.6. Auxiliary Control Oil Pump
The turbine will have a Positive displacement type auxiliary control oil pump,
mounted on base plate and driven by AC motor.
6.5.4. OIL FILTERS
One (1) duplex lube oil filter and one (1) duplex control oil filter will be provided
each with change over device. The Lube oil filter will be capable of filtering oil, to a level

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of 25 microns and the control oil filter will be capable of filtering oil, to a level of 10
microns.
6.5.5. OIL MIST FAN
Two (2x100%) oil mist fan will be provided for evacuating oil vapour from the oil
tank. The fan will be mounted on top of the tank and the discharge to atmosphere will be
provided with necessary oil catcher arrangement to entrap escaping oil.
6.5.6. LUBE OIL PURIFIER
An Oil purifier will be provided with necessary filters and heater, including the
pump and motors of the purifier system. The purifier is an off-line equipment meant to
clean the oil in the system by partial recirculation (operated for one shift per day).
Desludging of the purifier shall be done manually – periodically. The System will purify
the re-circulating Lubricating oil from entrained moisture & suspended solids. The
purifier capacity will be 1000 litres per hour.
6.6. TURNING GEAR
When the unit is under shutdown for a long period, due to its inherent weight, the
rotor shaft sags. Rolling of the unit with this condition will result in contact of the moving
parts with the stationary parts. Following tripping of the machine, due to condensation of
the locked up steam, the rotor shaft tends to hog. In order to prevent sagging and hogging
of the rotor shaft, a barring gear shall be provided. The barring device shall be capable for
automatic engagement and disengagement. The barring gear shall be operated by an AC
motor. In case of AC mains failure, provision for hand barring of the rotor shall be made.
6.7. MAIN STEAM STOP VALVES
6.7.1. EMERGENCY STOP VALVE
A hydraulically Operated Emergency stop valve shall be provided for closing the
supply to the Turbine under emergency condition.

2 x 18 MW CPP
PP 030 M B01 0 1 20
6.7.2. GOVERNING VALVE
Governing valves for the turbines will be of bar lift and multi valve type & will be
used for speed regulation of the turbine..
6.8. MAIN TECHNICAL PARAMETERS OF EACH TURBINE

Parameter Unit Value
Power at generator terminal kW 18000
Main Steam Pressure at Turbine inlet Ata 85
Main Steam Temperature at Turbine °C 510
inlet
Main Steam Flow at Turbine inlet TPH 76.4
Main steam requirement for auxiliaries TPH 0.5
Exhaust steam Pressure Ata 0.2
7. BOILER AND AUXILIARIES

7.1. GENERAL
The boiler is of top supported single drum natural circulation, semi-outdoor type,
fluidised bed combustion with under-bed fuel feeding system designed for firing:
Pet coke in combination with imported coal (70:30 Ratio on heat value)
(Dominant Fuel Mixture)
Pet coke in combination with Indian coal (70:30 Ratio on heat value) and
100 % Indian Coal.
100% Imported Coal
The complete furnace section will be of fusion welded wall type arranged as a gas
and pressure tight envelope. The circulation system will be complete with the necessary
number of down comers, supply and riser tubes piping. Steam separators are provided in the
steam drum to maintain the steam purity.
The convection superheater ( Primary & Sec SH ) will be located at the furnace exit
. Final superheater ( InBed SH ) will be located in the furnace bed. Inter-stage
desuperheater will be provided in between Primary & secondary superheater to control the
final steam temperature from the unit. The location, selection and arrangement of the
2 x 18 MW CPP
PP 030 M B01 0 1 21
superheater sections will be so chosen that the rated steam temperature at the superheater
outlet is achieved between 60 to 100% MCR load at 70 % petcoke : 30 % imported coal (
on heat o/p basis ) firing. SS 304 studs are welded on to in bed evaporator and superheater
coils to minimise erosion of the tubes.
The boiler will be provided with bare tube economiser fabricated from plain
seamless tubes. The boiler will also be provided with a tubular air heater as the last stage
of heat recovery unit. Provision for Installing Steam coil type air preheater in future has
been considered.
The complete integral piping, valves, fittings and pipe supports will be provided for
efficient operation of the boiler.
The fuel feeding system will consist of drag chain feeders / rotary feeders and fuel
feed lines. The crushed fuel is pneumatically transported and fed to the fluidised bed. The
fluidised bed is located at the bottom most part of the furnace.
Boiler is of top supported type and supported on the structural steel. The required
structural supporting steelwork for the boiler, galleries, staircases and outer casing will be
provided for the boiler, auxiliaries, ducting etc.
The boiler will be provided with one (1) each of ID, FD and PA fans and the
complete air and gas ducting with required dampers and expansion joints. ID fan for each
boiler will be provided with Variable Frequency Drive , FD fan & PA fan will be provided
with constant speed drive.
The feed water system will consist of three (3) motor driven feed pumps (with
constant speed drive) common for both the boilers, together with complete piping, valves
and other fittings.
Necessary lining and insulation along with fixing materials will be supplied.
All required actuators and controls and instrumentation will be supplied.

2 x 18 MW CPP
PP 030 M B01 0 1 22
A brief outline of the various sections of the proposed boiler and auxiliaries are
presented in the following paragraphs.
7.2. BOILER PRESSURE PARTS
7.2.1. ARRANGEMENT OF PRESSURE PARTS
Boiler will have steam drum and be designed for natural circulation with single
pass design. Boiler will be top supported on supporting structure. The furnace will be
formed by fusion welded membrane wall panel on the top of the furnace and with
refractory on bottom of the furnace.
STEAM DRUM
Steam drum will be of welded construction, completely radiographed to prove weld

soundness, stress relieved and hydraulically tested. The boiler quality plate for the drums
will be fabricated to the appropriate specification and constructed in accordance with the
codes and regulations of Indian Boiler Regulations.
Drum will be provided with suitable Tori Spherical dished ends and manholes, each
with a swing type cover opening internally and internal extension pipes will be fitted in the
drums as appropriate to ensure uniform distribution or collection for the duty involved.
The steam drum will be of fusion welded construction, with material specification
conforming to SA 516 Gr. 70. The steam drum will have nozzles for routing piping to
connect the primary superheater header.. Nozzles will also be provided for the external
mounting of safety valves, water level gauges, water level alarms, water level regulators,
pressure gauges, continuous blowdown, feed water inlet, chemical injection, sampling, air
vent and any other users of steam from the drum.
Suitable internal for feed distribution, continuous blow down and chemical dosing
will also be provided in the steam drum.
The internals of the steam drums will be designed to provide steam of high purity.
Steam drum will be equipped with cyclone separators, followed by two stage screen dryers
to achieve required steam purity.
2 x 18 MW CPP
PP 030 M B01 0 1 23
Details of Boiler Steam Drum is as follows :-
a) Design Code IBR : 1950
b) Construction Welded
c) Material Specification SA 515 Gr. 70
d) Inside Diameter 1375 mm
e) Thickness 67 mm
f) Length on the straight 6000 mm
g) Over all Length 7124 mm
h) Drum internal Cyclone Seperator with

primary & Secondary
screens
7.2.2. STEAM DRUM
Steam drum will be of welded construction, completely radiographed to prove weld

soundness, stress relieved and hydraulically tested. The boiler quality plate for the drums
will be fabricated to the appropriate specification and constructed in accordance with the
codes and regulations of Indian Boiler Regulations.
Drum will be provided with suitable Tori Spherical dished ends and manholes, each
with a swing type cover opening internally and internal extension pipes will be fitted in the
drums as appropriate to ensure uniform distribution or collection for the duty involved.
The boiler drum shall be sized such that the capacity between normal level and low low level shall
be sufficient to run the unit for 1 minute with feed water flow stopped.
The steam drum will be of fusion welded construction, with material specification
conforming to SA 516 Gr. 70. The steam drum will have nozzles for routing piping to
2 x 18 MW CPP
PP 030 M B01 0 1 24
connect the primary superheater header.. Nozzles will also be provided for the external
mounting of safety valves, water level gauges, water level alarms, water level regulators,
pressure gauges, continuous blowdown, feed water inlet, chemical injection, sampling, air
vent and any other users of steam from the drum.
Suitable internal for feed distribution, continuous blow down and chemical dosing
will also be provided in the steam drum.
The internals of the steam drums will be designed to provide steam of high purity.
Steam drum will be equipped with cyclone separators, followed by two stage screen dryers
to achieve required steam purity.
Details of Boiler Steam Drum is as follows :-
a) Design Code IBR : 1950
b) Construction Welded
c) Material Specification SA 515 Gr. 70
d) Inside Diameter 1375 mm
e) Thickness 67 mm
f) Length on the straight 6000 mm
g) Over all Length 7124 mm
h) Drum internal Cyclone Seperator with

primary & Secondary
screens

2 x 18 MW CPP
PP 030 M B01 0 1 25
7.2.3. FURNACE WALLS AND HEADERS
7.2.3.1. Furnace
The furnace will be of fully water cooled construction, formed by membrane water
walls. Furnace tubes will be of seamless, carbon steel conforming to SA 210 Gr. A1
material specification. Tube ends terminating at headers will be welded to stub tubes
provided on the headers. The furnace walls will be strengthened by providing buckstays
and tie bar system to withstand furnace pressure..
7.2.3.2. Front Wall
The front wall will be formed with tubes extending from the lower supply header
upwards. The panel tubes then connect to the top header and from the top header, risers
tubes are routed to the steam drum.
7.2.3.3. Rear Wall
The rear wall will be formed of tubes extending from the lower supply header
upwards and forming the furnace arch.. Panel Tubes then connect to top header and from
the top header, riser tubes are routed to the steam drum.
7.2.3.4. Side Walls
The side walls will be formed of tubes extending from the lower supply headers to
the upper riser headers. From the upper headers, the steam-water mixture will be routed to
the steam drum by means of riser tubes. Overfire air nozzles will be provided, as required.
7.2.3.5. Inbed Evaporator
The inbed evaporator coils will be provided in the furnace bed, forming part of
circulating system of the Boiler. The pitch of the tubes will be wider enough to avoid
erosion of tubes. The coils are studded with SS 304 material at the bottom portion and
bends.

2 x 18 MW CPP
PP 030 M B01 0 1 26
7.2.3.6. Headers
The headers will be of adequate size and design in accordance with Indian Boiler
Regulations, and the material specification will conform to SA 106
Gr. B. The necessary drain connections and hand-holes will be provided as required.
The connections to the steam drum and the connections to the headers will be
designed so as to form an integral circuit providing adequate natural circulation under all
operating conditions.
All headers will be provided with extended pipes and end caps welded.
7.2.4. SUPERHEATERS AND DESUPERHEATER
The superheaters will comprise primary and secondary coils located in the
convection and radiant zones respectively and will be complete with all manifolds, fittings,
supports, supply and drain connections.
Convection superheater and bed superheater sections will be a combination of

seamless tubes. The method of suspension of the section will be designed to permit free
expansion of the coils. Bed superheater coils will be studded with SS 304 material.
The desuperheater will be located in the steam pipe between the primary and
secondary superheaters and will control the superheater outlet temperature. This inter
stage desuperheater will be of spray type and necessary spray nozzle and inner section of
desuperheater will be provided stainless steel liners. The spray water for the desuperheater
will be derived from the feed pump discharge, through a desuperheater control station.
Provision by way of openings in the pressure part will be kept for Soot blower in
primary super Heater zone of boiler.
7.2.5. ECONOMISER
The economiser will be made of bare carbon steel tubes conforming to SA 210 Gr
A1 seamless and of continuous loop type with inlet and outlet headers. It will be

2 x 18 MW CPP
PP 030 M B01 0 1 27
supported in a structural steel frame and enclosed within welded steel casing. Doors will
be provided for observation and also access for maintenance.
The economiser will be complete with the necessary drains, vents, thermometer
pockets and pressure gauge connections.
7.3. BOILER MOUNTINGS AND FITTINGS
The Boiler will be provided with a complete set of mountings and fittings in
accordance with the Indian Boiler Regulations, for the safe operation of the Boiler and the
details of the mountings and fittings including:
7.3.1. STEAM DRUM
-Safety valves
-Continuous blow down (CBD) valves
-Air vent valves
-Pressure gauge with isolation valves
-Chemical dosing valves and check valve
-Sampling valves for CBD and saturated steam
-Valve for steam drum auxiliaries
-Isolation valves for pressure transmitters
-Isolation valves for level transmitters
-Direct water level gauges with isolation and drain valves
- Remote water level gauge (EDLI)
7.3.2. DRAIN HEADER
-Isolation valves
7.3.3. SUPERHEATER
-Safety valve (secondary outlet) with silencer

-Motor operated main steam stop valve with integral by-pass valve
-Steam outlet check valve
2 x 18 MW CPP
PP 030 M B01 0 1 28
-Pneumatic operated vent valve capable of manual inching during start up,
with silencer and one isolation valve. Start-up vent will be sized for 30% of
BMCR capacity.
-Pressure gauges with isolation valves and drain valves
-Sampling valves
-Drain valves
-Air vent valves
-Valves for pressure transmitters and flow transmitters
-Main steam flow nozzle
-Thermometers
-Steam distribution header with motorised isolation valves
-Drain assembly for distribution header
-Pressure gauge with isolating valve
-Air vent valves
Formatted: Bullets and Numbering
7.3.4. SPRAY WATER LINE
-Spray water regulating valve

-Spray water regulator isolating valves
-Spray water regulator by-pass valve with two (2) isolation valves
-Spray water check valve
-Isolation valve for desuperheater inlet
-Drain valves
7.3.5. ECONOMISER
-Drain valves
-Pressure gauge with isolation valves
-Air vent valves
7.4. SOLID FUEL FIRING SYSTEM
The boiler will adopt atmospheric fluidised bed combustion system and the fuel
firing system will be designed for `under bed feeding' system. The boiler is capable of
firing the following fuels:
2 x 18 MW CPP
PP 030 M B01 0 1 29
•Pet coke + Imported coal 70%+30% (on heat value basis)
•Pet coke + Indian coal 70%+30% (on heat value basis)
•Imported coal – 100 %
•Indian coal – 100%
7.4.1. FUEL & LIME STONE / BED MATERIAL BUNKER
Each boiler will be provided with following bunkers of Mild Steel construction.
9 Indian Coal / Imported Coal bunker

9 Petcoke bunker
9 Lime stone cum bed material bunker
7.4.1.1. Bunker sizing basis

Sl Description Basis of design Consumption of Bunker Bunker
material , TPH capacity Water
required, volume
Metric Ton
a) Coal bunker 100% Indian coal Consumption of 16.802 400 m3
firing , 16 hrs coal at 100% TPHx16 hrs
storage BMCR : 17.1 = 268.83 T
TPH
c) Lime stone Lime stone dosing Consumption of 4.882 TPH 115 M3 Deleted: 4.09
cum bed during Petcoke Lime stone at x 24hrs = Deleted: 65
material firing at 70% with 100% BMCR : 117.16 T Deleted: 16
bunker 30% Imported 4.09 TPH Deleted: 65.44
coal on heat value
basis for Sulphur
Capture, 24 hrs
storage
Note : -
1. Bulk density of different materials are considered as follows
- Indian / Imported Coal , Petcoke : 800 kg/m3

2 x 18 MW CPP
PP 030 M B01 0 1 30
Lime stone : 1200 kg/m3
The Bunker shall be divided in two sections, one for Petcoke Storing and another for
Indian coal / Imported coal.
The Petcoke bunker water volume capacity is 200 m3 and Indian / Imported coal
is 200 m3.
The bunker will be adequately stiffened and covered at the top, leaving necessary
opening for conveyor chutes.
The bunker will be provided with necessary support steelwork from ground level.
The design of the bunker should take care of free flow of fuel by providing a valley angle
of not less than 60o.
7.4.2. FUEL FIRING SYSTEM
The fuel firing system will be designed to burn maximum particle size of 6 mm
with a fine content (less than 1 mm size) not exceeding 30%.
For each boiler there are separate bunkers for Indian Coal / Imported coal, Petcoke
and limestone/ bed material. Limestone is fed to a drag chain feeder through VFD Screw
feeder. ( Rev 1 ). Bed material is filled by over bed feeding arrangement, For this tapping
is taken from limestone bunker ( 1, 3 & 5 ) and connected to the bed material cum peep
hole arrangement chute on the side walls. (Rev 1), Knife edge gate valves are provided for
isolation The pet coke is fed to the drag chain feeder through VFD operated Rotary feeder
which discharges to the mini hopper at the exit of Drag chain feeder. Indian Coal /
Imported coal is fed into Drag chain feeder. The Drag chain feeder speed is also controlled
through VFD. The combined fuel is taken pneumatically to the furnace through venturi and
PA (primary air) line.
Knowing the sulphur content in pet coke from laboratory analysis and measuring
the sulphur dioxide content in the flue gas by portable analyser from time to time, the ratio
of pet coke to lime stone can be varied to achieve the designed sulphur capture in the bed.

2 x 18 MW CPP
PP 030 M B01 0 1 31
The ratio of pet coke and coal also can be varied to suit the requirement of stable
and economic operation within the design limit.
7.4.3. FLUIDISED BED
The fluidised bed will consist of five ( 5 ) compartments (sections). Each section
will be provided with four- (4) stainless steel fuel feeding nozzles and adequate number of
stainless steel fluidising air nozzles fitted on to the distributor plate. Bed superheater and
evaporator coil will be provided in the bed, to maintain the bed temperature.
7.4.4. ASH DISCHARGE SYSTEM
Bed drain pipes, one (1) for each segment is provided to remove the ash through
ash cooler and to maintain the correct bed height. In addition to this, drain points are
provided in the distributor level to drain out the entire material, if required. There will be
five (5) numbers bed ash discharge point from furnace. The bed drain (emergency drain)
will be terminated 1m above ground.
The fly ash collected in the economiser hoppers and air heater hoppers shall be
delivered to the ash conveying system..
7.5. AIR AND FLUE GAS SYSTEMS
7.5.1. DRAFT SYSTEM
The draft system for the boiler will consist of:

One (1) Forced Draft (FD) fan of 100% boiler MCR capacity supplying the
necessary amount of combustion air for fluidised bed combustion of the
different fuels with sufficient pressure to overcome the resistance of ducts,
measuring devices, dampers, fluidising air nozzles, air heater and burners. The
suction is taken from atmosphere with inlet damper control. FD fan shall be
provided with Constant Speed drive. FD fan bearings will be provided with
Grease Lubrication.
One (1) Induced Draft (ID) fan of 100% boiler MCR capacity handling the
combustion gas from the outlet of electrostatic precipitator. The fan will have
sufficient head to overcome the draft loss of furnace, secondary superheater,
2 x 18 MW CPP
PP 030 M B01 0 1 32
boiler bank, primary superheater, economiser, air heater, ESP and ducts. An
isolating damper in the discharge duct and a control damper in the suction duct
will be provided. The fan will be of centrifugal type with flexible coupling. ID
fan drive will be provided with variable frequency drive. ID fan bearings will
be provided with Grease Lubrication.
One (1) Primary Air (PA) fan of 100% boiler MCR capacity, boosting hot air
pressure from air heater outlet, serves as a means for transporting the crushed
fuel from the fuel feeder outlet to the various points of the fluidised bed for
combustion. PA fan bearings will be provided with Grease Lubrication.
Sizing of FD , ID and PA fan are as follows
FD Fan ( Rev 1)
Sl Description Unit Test PC + Imported PC+ Indian
Block Imported Coal Indian Coal
condition Coal Coal
1 Capacity Calculation
a) No. of fan No. 1
b) Design Temp. °C 45 35 35 35 35
c) Fuel Flow Kg/hr 10485 8202 9379 10485 16802
d) Excess air % 20 20 20 20 20
e) MCR air flow
Kg/hr 93458 93147 89276 93458 90750
(wet)
f) Air flow Kg/S 25.96 25.87 24.80 25.96 25.21
g) Margin % 20 0 0 0 0
h) Test block flow Kg/s 31.15 25.87 24.80 25.96 25.21
i) Density of air Kg/m3 1.045 1.079 1.079 1.079 1.079
j) Test Block flow M3/s 29.81 23.98 22.98 24.06 23.36
2 Head Calclation
a) DP Bed MmWC 540 540 450 540 450
b) DP flow MmWC 25 25 23 25 24

2 x 18 MW CPP
PP 030 M B01 0 1 33
measuring
c) DP Silencer MmWC 25 25 23 25 24
d) DP APH MmWC 30 30 27 30 28
e) DP Scaph (if
Mmwc 25 0 0 0 0
required)
f) DP bubble Cap MmWC 198 197 181 198 187
g) DP Duct &
MmWC 25 25 23 25 24
damper
h) DP total MmWC 870 842 727 843 737
i) Margin on
% 25 0 0 0 0
variable head
j) Test block DP MmWC 950 850 730 850 740
ID Fan ( Rev 1)
Sl Description Unit Test PC + Importe PC+ Indian
Block Importe d Coal Indian Coal
conditio d Coal Coal
n
a) No. of fan No. 1

b) Design Temp. °C 165 150 140 150 140
c) Fuel Flow Kg/hr 10485 8202 9379 10485 16802
d) Excess air %
28 28 28 28 28
(incl infiltration)
e) MCR gas flow Kg/hr 10703
106233 102891 107034 105671
(wet) 4
f) Gas flow Kg/S 29.73 29.51 28.58 29.73 29.35
g) Bed ash cooler Kg/s
2.00 0 0 0 0
gas
g) Gas flow Kg/s 31.73 29.51 28.58 29.73 29.35

2 x 18 MW CPP
PP 030 M B01 0 1 34
h) Margin % 20 0 0 0 0
i) Test block flow Kg/s 38.08 29.51 28.58 29.73 29.35
j) Density of air Kg/m3 0.773 0.804 0.812 0.803 0.808
k) Test Block flow M3/s 49.26 36.70 35.20 37.03 36.33
2 Head Calclation
a) Furnace Pressure MmWC 5 5 5 5 5
b) DP SH MmWC 5 5 5 5 5
c) DP eco mmWC 25 25 23 25 24
d) DP AH mmWC 35 34 32 35 34
e) DP ESP mmWC 25 25 23 25 24
f) DP duct mmWC 25 25 23 25 24
g) DP damper mmWC 15 15 14 15 15
h) DP chimney 10 10 9 10 10
i) DP total mmWC 145 144 134 145 141
j) Margin on head % 35 0 0 0 0
j) Test block Head mmWC 200 145 135 145 145
PA Fan
Sl Description Unit Test Block PC + Imported
condition coal
Indian coal
Imported coal
PC + Indian coal
a) No. of fan No. 1 1
b) Coal Feed line NB 125 125
c) Total Air required M3/hr 4.69 4.69
d) Margin on fan % 20 0
e) Test block flow M3/s 5.62 4.69

2 x 18 MW CPP
PP 030 M B01 0 1 35
f) Air temp Deg C 175 160

f) Density of hot air Kg/m3 0.798 0.816
2 Head Calclation PC+Imp. Ind
PC+Ind Coal/
Imp
Coal
a) DP bed mmW 540 540 450
C
b) DP Line mmW 50 50 50
C
c) DP ventury mmW 800 800 800
C
d) Margin mmW 100 0 0
C
e) DP MCR mmW 1490 1390 1300
C
f) Fan inlet mmW 725 725 625
C
g) DP differntial mmW 765 665 675
C
h) Test block DP mmW 850 665 675
C
7.5.2. DUCTWORK AND DAMPERS
Ducts will be sized considering a maximum velocity of 12 m/sec for hot air and
flue gas applications of the ducts will be rectangular in cross section and will be of welded
construction, properly stiffened and reinforced. All ducts handling air and flue gas will be
fabricated with carbon steel plates of thickness not less than 5 mm for air and 6 mm for
gas. The carbon steel plates will be as per IS:2062. Alloy steel ducts will be provided, at
regions where flue gas temperature exceeds 420oC. Duct corners will have stitch weld
internal and external full weld.
2 x 18 MW CPP
PP 030 M B01 0 1 36
Internal struts will be provided for ducts, these will be generally of tubular truss
work, at load transferring points heavier truss work will be provided. Internal struts will
be of ERW tubing. The ducts will be provided with necessary supporting either from the
ground or from the boiler supporting steel work depending on the locations. All ducts
exceeding 1000 mm (width or depth) will be shipped as loose walls for assembly at site.
Expansion joints will be provided as applicable and will be made of 2.5 mm thick
carbon steel / alloy steel sheets as applicable.
Necessary dampers will be provided, complete with actuators, visual position

indicators and means of securing as required by the design.
7.5.3. AIR HEATER
The boiler will be provided with an air heater with gas flowing through the tubes to
recover heat from flue gas and pre-heat the combustion air.
7.6. THE AIR HEATER WILL COMPRISE CARBON STEEL TUBES OF

MATERIAL SPECIFICATION BS 6323.FEED WATER SYSTEM
The feed water system for both the boilers comprise one (1) common deaerator-
cum-feed storage tank, three (3) feed water pumps each of 100% MCR capacity, of each
Boiler. Feed control station and feed line from the feed pump suction manifold of deaerator
to steam drum through HP heater.
7.6.1. DEAERATOR
The deaerator will be common for both boilers to supply deaerated feed water at
154oC at full load. Deaerator will be sliding pressure deaerator. Necessary piping
associated with deaerator will be included. The storage vessel will be of sized to meet at
least 10 minutes’ requirement (between normal level and low-low level) of two (2) boilers
running at MCR. The storage vessel will be mounted at suitable height to provide the
required NPSH for the feed pumps.
The deaerator unit will be complete with necessary internal trays, water sprays,
water level control system and temperature control system, vent condenser, safety valve

2 x 18 MW CPP
PP 030 M B01 0 1 37
and vacuum breaker. The storage tank will be complete with water level indicator and
alarm, access ladders and platforms.
Chemical dosing would be performed inside the Deaerator by means of sparger

pipe inside the storage tank.
Steam for heating will be supplied from the extraction of turbo alternator.
Provision will also be made for supply of steam from the Common Superheated Steam
header through a system of pressure reducing valve during start up & low load operation.
Flash steam from blow-down tank is also utilised for the Deaerator. The Deaerator
pressure will be maintained constant through Pressure Control Station. The oxygen
content on the outlet water will not be more than 0.007 ppm.
Details of Deaerator & Feed water storage tank is as follows.
1) Deaerator
a) Dimension ID 2000 mm X 2500 mm HT
b) Type Spray & Tray type
c) Design de-aeration Capacity 176 m3/hr
2) Feed water storage tank
a) Diameter 3500 mm ID
b) Length 8500 mm (Approx.)
c) Capacity at operating level 29.33 m3 (between normal &

trip level)
(Capacity = 10 minutes)
7.6.2. FEED PUMPS
Three (3) electrically driven feed pumps with all pipe works and valves will be
supplied for the boilers. The pumps will be identical and interchangeable. The pump

2 x 18 MW CPP
PP 030 M B01 0 1 38
design will have a capacity equal to 100% of each boiler MCR and it will be of multistage
centrifugal type, complete with suction strainer, balance chamber and necessary suction
and delivery valves, non-return valves and automatic minimum flow recirculation valves to
cater for start-up and low flow conditions, gland sealing with mechanical seals and bearing
cooling pipe work, valves, pressure and temperature indicators. The feed pumps will be
provided with minimum flow automatic recirculation lines will discharge to deaerator via
isolating and non-return valves. The pumps will be supplied with necessary suction and
discharge lines.
Motorised valves will be provided at the discharge of the Boiler Feed Water
Pumps. The BFP will be interlocked to start only if discharge pressure in header is above a
predetermined value or outlet MOV is closed. On trip of a pump, the standby pump will
start automatically.
The suction lines for the feed pumps will be tapped from a nozzle of the deaerator,
at a suitable elevation. Isolating valves will be provided at both suction and discharge
ends with pressure gauges. A check valve will be provided at the discharge line. Online
strainer with facility for removal for cleaning will be provided on the suction line. One (1)
differential pressure indicator will be provided for the suction strainer, with alarm
provision to indicate choking of strainer.
The pump and motor will be mounted on a common base frame and provided with
a flexible coupling and guard. Coupling halves will be properly balanced.
Boiler Feed Pump Sizing
For boiler feed pump sizing 5% margin will be provided on flow and 5% margin will be
provided on head calculated base on 2nd safety valve set pressure. With such margin , it shall
be checked and ensured that even at 47.5 Hz frequency the boiler feed water pump is
capable of delivering 100% BMCR flow rate and required head during MCR operation of
boiler. The BFP sizing basis is as follows.

2 x 18 MW CPP
PP 030 M B01 0 1 39
Pump Capacity Calculation
Boiler MCR flow rate 80 TPH
Feed water flow at MCR 80 TPH
Feed water density at 154 °C 913.27 kg/m3 (Rev 1)

temperaturen ( Rev 1 )
MCR volume flow 87.62 m3/hr ( Rev 1)
Blow down 3% added 2.62 m3/hr ( Rev 1)
Margin 5% 4.38 m3/hr ( Rev 1)
Calculated Test block flow 94.62 m3/hr ( Rev 1)
Selected Test block flow 94.75 m3/hr ( Rev 1)
b) Pump Head Calculation
Boiler design pressure based 104.00 kg/cm2(g)

on 2nd drum safety valve set
pressure
Pressure drop in piping 1.5 kg/cm2(g)
HP heater pressure drop 1.0 kg/cm2(g)
Pressure drop Across Eco 1.0 kg/cm2(g)
Pressure drop across Control 1.5 kg/cm2(g)

valve & orifice
Static Head 2.5 kg/cm2(g)
Suction Head (-) 3.0 kg/cm2(g)
Head at BFP suction :
Static head : 14.5 m
D/E opr. Pr. : 4.36

kg/cm2(g).
Total head : 5.81

kg/cm2(g)

2 x 18 MW CPP
PP 030 M B01 0 1 40
Line losses + strainer

loss = 0.5 kg/cm2(g)
Net available pr. =

5.31 kg/cm2(g).
Suction head
considered for calcs :
3kg/cm2(g).
Calculated TDH 108.50 kg/cm2(g)
Margin 5% 5.375 kg/cm2(g)
Calculated Test block TDH 113.925 kg/cm2(g)
=1247.80MLC (Rev 1)
Selected Test block TDH 1250.00 MLC ( Rev1)
7.7. BOILER STRUCTURES AND AUXILIARIES
7.7.1. STRUCTURAL STEEL
The complete structural steel necessary to support/suspend the various components

and equipment, ducts etc will include all auxiliary columns, duct supporting columns,
bracing, and all equipment structures etc. All structural steel will be designed for
horizontal seismic forces as applicable under the latest Revision of IS 1893/75 and wind
forces as per latest revision of IS 875/67, whichever governs the design. All structural steel
work will be designed as per IS 800 and material specification conforming to IS 226/68, IS
2062/62 or equivalent. The structure will incorporate necessary lifting beams and hoist
blocks required for maintenance of fans, pumps etc.
7.7.2. PLATFORM, STAIRWAYS AND GRATING
A complete system of platforms around boiler, at feed water control station, at main
steam outlet header, at fuel feeder floor, etc will be provided and stairways will be
provided to enable access to various parts of the boiler. The stairways will be provided on
one side of the boiler. Handrails will be provided for all stairways and platforms as per

2 x 18 MW CPP
PP 030 M B01 0 1 41
relevant engineering standard and also as required by Inspector of Factories. Boiler

platform & stair case width will be minimum 750 mm.
7.8. REFRACTORY AND INSULATION
7.8.1. GENERAL
The boiler will be complete with all the necessary castable refractory and refractory
bricks and blocks as required for the furnace and generator bank areas, together with all
the necessary insulating blocks, bricks and mattresses and all the requisite fixings, holders
and other attachments. The refractory and insulation materials will comply with the
relevant Indian standards.
7.8.2. DESIGN TEMPERATURE DIFFERENTIAL - CRITERIA
The thickness of wool mattress will be calculated based on a differential

temperature of 20oC between ambient (as measured one (1) m from outer casing). This
will be applicable, irrespective of ambient temperature. Insulation will be provided for
equipment and ducts where the temperature exceeds 60oC.
7.8.3. EXTERNAL INSULATION
The machine made mineral wool mattresses will be used as external insulating
layer and will have a uniform density of 150 kg/m3. The mineral wool specifications and
thermal conductivity figures will be as per IS: 3677.
The wire netting to be provided on both sides of mattresses will be of SS material.

Mesh size will be as per IS: 3150 - N2 type.
7.8.4. BINDING AND STITCHING WIRE
The binding and stitching wire used for fixing the insulation materials will be of GI
material and of dia (min 1.0 mm) - normal 1.219 mm, stitching wire will be of 0.711 mm
diameter

2 x 18 MW CPP
PP 030 M B01 0 1 42
7.8.5. ANTI-CORROSIVE PAINTING FOR OUTER CASING
For the inner side of outer casing sheets, two coats of anti-corrosive, black
bituminous paint, as per IS:159, will be applied before the outer casing is installed.
7.8.6. OUTER CASING
The main boiler section (furnace and bank tubes) will be enclosed with corrugated
aluminium sheet casing of 0.711 mm thick. The ducts, boiler integral piping and vessels
etc will be enclosed with plain aluminium sheet of 0.711 mm thick.
The non-membrane pressure parts will be enclosed in a 5 mm thick sheet metal

casing to prevent air leakage and the top will be covered with plates laid to a fall. The
maximum skin temperature of the lagging will not exceed 20oC above ambient when the
boiler is operating at full load. The exposed portions of the boiler drums, integral
pipework, casings and the economiser, dust collector, flue gas ducting together with all
steam and feed water lines will be provided with necessary insulation and clad with
aluminium sheeting neatly attached.
Removable insulated boxes will be provided for valves and provision should made
for easy removal of the insulation at flanges, without affecting the general pipework
insulation.
All drain lines, vent and exhaust lines and all other items at high temperature will
be covered with a sufficient thickness of insulation, for personnel safety.
The necessary seals, expansion joints, door linings, and fire cement and all other
items to complete the installation will be included.
7.9. CHEMICAL DOSING SYSTEM
One (1) HP chemical dosing system with 3 numbers of dosing pumps (2 W+ 1S)
will be provided common for both boilers. However, LP chemical dosing system with 2
numbers of dosing pumps (1 W+ 1S) will be provided common for both boilers. The
chemical dosing system will be provided with all necessary chemical dosing pumps, pipe
work and fittings.
2 x 18 MW CPP
PP 030 M B01 0 1 43
7.10.SAMPLING LINES AND SAMPLE COOLERS
The sampling lines and sample coolers will be provided for feed water, drum water,
saturated steam and superheated steam. Sampling lines and nozzles will be of suitable
material to take care of high chloride content in Circulating Water. The sample coolers
will be located in boiler area.
7.11.BLOW DOWN TANKS
One (1) continuous blow down tank and one (1) intermittent blow down tank of
appropriate capacity shall be provided, common for both the boilers to receive all the
continuous and intermittent blow downs and all other drain discharges from the boilers.
The flash steam from the continuous blow down tank shall be utilised in the deaerator for
heating. Necessary level control station for the continuous blow down tank along with
safety valve and other fittings shall be provided.
The intermittent blow down tank, together with the internal piping and vent, is
designed to maintain a water-sealed discharge to the effluent drain. It will be complete
with necessary supports and ancillaries including an inspection manhole. Vent pipe of
adequate size will be extended by at least 1 m from the top of the roof. The tank will
normally work at atmospheric pressure and the design will comply with the appropriate
regulations.
7.12.ELECTROSTATIC PRECIPITATOR
The ESP will be designed to handle the flue gases generated from the different
fuels that would be burnt in the AFBC Boiler. The worst fuel is considered for design. The
following table gives the gas data for the various fuels considered for design:
FUEL IDENTIFICATION PETCOKE + IMPORTED PETCOKE + INDIAN

IMPCOAL + LIME COAL IND COAL + COAL
STONE LIME STONE
( PERFORMANCE )
1.LOAD CASE –I CASE –II CASE-III CASE –IV
2.GAS FLOW (m3/sec) 40.50 37.10 38.85 38.20
3.GAS TEMPERATURE (DEG.C) 150 140 150 140
4.GAS ANALYSIS ( % VOL WET)

2 x 18 MW CPP
PP 030 M B01 0 1 44
CO2 14.24 14.68 14.30 13.11

H2O 8.08 10.85 8.40 11.86
N2 74.04 70.73 73.43 71.59
O2 3.51 3.70 3.75 3.38
SO2 0.11 0.034 0.12 0.045
5.GAS DENSITY
1.323 1.302 1.321 1.297
(kg/Nm3)(WET BASIS)
6.DUST CONCENTRATION
56.1 16 73.65 64.05
(Gm/Nm3)AT ESP INLET
7.SUCTION AT MCR (mm Wc) -125 -120 -125 -120
8.MAX. SUCTION (mm Wc) -185 -185 -185 -185
9.UNBURNT CARBON IN
65 – 80 * 20 - 25 30 –40* 5 – 10
GRITS %
10.CLEAN GAS BURDEN
(mg/Nm3 )AT ESP OUTLET
50
WITH ALL FIELDS IN
SERVICE
11.SPENT SORBENT(KG/GR) 3911 NIL 3967 NIL
12.FUEL FLOW (KG/HR) 8202 9379 10485 16802
Note:
*1.THE FLY ASH CONTAINS REACTED LIMESTONE, UNREACTED LIMESTONE, CALCIUM
SULPHATE AND UNBURNT CARBON & ASH (CACO3, CA0, CASO4, C ,ASH )
2.GAS QTY IS ALREADY CORRECTED FOR TEMP.,SITE ELEVATION(372.00 MTS FROM
MSL), & PRESSURE OF GAS AT SUCTION ETC
3. BOTTOM LEVEL OF HOPPER WILL BE AT 2.50 M ELEVATION
4. The maximum pressure drop across the ESP will be 25mmwc.
PARTICLE SIZE DISTRIBUTION
Size(Microns) PERCENTAGE Size(Microns) PERCENTAGE

PASSING PASSING
1190 99.918 % 149 92.48 %
595 99.63 % 105 72.90 %
297 97.795 % 77 53.60 %
250 96.80 % <44 25.72 %.
FUEL ANALYSIS ( % BY WEIGHT ) ULTIMATE ANALYSIS
PETCOKE + IMPORTED PETCOKE + IND INDIAN COAL

FUEL IMPCOAL COAL COAL
(PERFORMANCE)
CARBON 77.73 60.5 61.24 34.2
HYDROGEN 3.76 4.6 3.03 2.75
ASH 5.16 14 22.16 45
MOISTURE 3.80 9 4.42 8.00
NITROGEN 0.98 1.5 1.58 2.5
OXYGEN 3.89 10 3.84 7.25
SULPHUR 4.69 0.4 3.73 0.3
GCV, KCAL/KG 7319 6055 5755 3400

2 x 18 MW CPP
PP 030 M B01 0 1 45
B. ASH ANALYSIS :
PETCOKE IMPORTED COAL INDIAN COAL

Aluminium AS AL2o3 28.59 25 25
Calcium AS CAO 0.33 10 1.1
Chlorides as CI TRACES -
Iron as fe2o3 7.27 15 7.75
Magnesium as Mgo 0.26 4 1.6
Phosphorous as P2o5 0.26 0.1 0.05
Potassium as k2o 1-2 0.03
Silica as Sio2 60.10 35 61.2
Sodium as Na2o 1-2 1.1
Sulphur as So3 - 0.5
Titanium as Tio2 1.96 0.8 1.4
Total carbonates as - -
Co3
Other Oxides -
Magnesium oxide as - -
Mn3o4/Mno
Shulphuric anhydrate 0.33
Alkalies (Na2o +k2o) 0.79 1.14
Vanadium 0.11
Nickel traces
The aspect ratio of the ESP (electrode zone) will be optimally selected so as to
minimise re-entrainment and carry over of the collected dust. The ESP will be provided
with four nos. of independent electrical fields with all associated electrical system,
controls, cables, panels, hoppers, etc.,each field will have independent HV TR sets with all
associated electricals, controls, cables, panels.
The Housing & ducting will be gas tight, weatherproof; welded steel envelope
suitably stiffened and fabricated from MS sheets with a minimum thickness of 5mm.
Necessary sealing arrangement to prevent moisture & air ingress into the casing will be
provided. Gas distribution screens will be provided to distribute the gas uniformly
throughout the ESP cross section area. The HT emitting electrodes shall be made of
durable and corrosion resistant material. They shall be accurately centred between the
collecting electrodes, duly supported to prevent swinging and will be properly insulated
from the precipitator casing. The collecting electrodes will be shaped in one piece by roll
forming and will be designed on the concept of dimensional stability and high collecting
efficiency. Independent rapping system will be provided for discharge & collecting
electrodes with independent control systems. The rapping mechanism will be electric
2 x 18 MW CPP
PP 030 M B01 0 1 46
impact type. The rapping system will have adjustable facility for frequency, intensity and
duration to provide an efficient cleaning rate. The gas distribution screens will also be
provided with the rapping system. The ESP will be provided with lifting/handling arrangement
consisting of a suitable monorail system for lowering / lifting the TR sets the during any
maintenance activity
The hot parts ducting and ESP will be suitably insulated thermally, either internally
or externally. The insulation material will be mineral wool blanket of adequate thickness
such that the exposed surface temperature does not exceed 60°C with 1 m/s ambient wind
velocity. The cladding material will be plain Aluminium sheet of 22 gauge for external
insulation.
The ESP will have mechanical & electrical interlocks for personnel protection. The
different parts of ESP, viz., Transformer, rectifier, Control panels, etc. will have lifting &
handling arrangements. The steel staircases will be at least 750 mm wide and not more
than 45° inclination to the horizontal plane.
8. STEAM FEED WATER AND CONDENSATE SYSTEM

8.1. STEAM SYSTEM
The steam system is mainly composed of: -
(A)Main steam system

Steam from each boiler at 89 kg/cm2(a) pressure and 515°C temperature is
provided to TG through dedicated pipe line. The main steam line for each unit
will be interconnected through a motorised normally closed isolation valve.
Main steam line will be provided with motor operated isolation valve in boiler
island and another motor operated isolation valve in TG area.
Following taping point will be provided in each individual main steam line to
each turbine
For steam jet air ejector auxiliary PRDS.
For turbine bypass system.
2 x 18 MW CPP
PP 030 M B01 0 1 47
For deaerator pegging steam line.
Suitable drain and vent connections shall be provided between isolation valves of
each Boiler in line with IBR requirements. These drain / vent isolation valves shall
be manually operated.
Each Boiler superheater outlet would be provided with safety relief valve for over-
pressure protection of Boiler superheater.
(B)Auxiliary steam system for steam jet air ejector

From each main steam line individual tapping will be provided to a PRDS
station for steam jet air ejector steam requirement. The pressure reducing &
desuper heating station will reduce steam temperature & pressure to 13
kg/cm2(a) & 300°C. Steam requirement for steam jet air ejector will be around
0.40 TPH (at 13 kg/cm2(a) & 300°C).
(C)HP steam system for HP heater

From each Steam Turbine Generator bleed at around 21 kg/cm2(a) will be
taken for HP heater. This line will be provided with Pneumatic operated quick
closing non-return valve (QCNRV) and motor operated valve.
(D)MP steam system for Deaerator

From each Steam Turbine Generator extraction will be taken for common
deaerator. MP extraction steam will be connected to a common header (MP
steam heater). Pegging steam line from Main steam will also be connected to
this header through a PRDS station. Each extraction line will be provided with
Pneumatic operated quick closing non-return valve (QCNRV) and motor
operated valve.
(E) Steam turbine bypass system

Turbine bypass system will be provided for start-up and during load throw-off
condition. Turbine bypass system will be sized for 25% of TMCR flow. From
each individual unit main steam line tapping will be provided to individual

2 x 18 MW CPP
PP 030 M B01 0 1 48
PRDS station to reduce main steam pressure and temperature to 3.5kg/cm2(a)

and 150°C respectively. Then this low pressure & temperature steam will be
provided to condenser steam dumping device (located on the steam exhasut
duct). Steam dumping during sudden load-through off will be initiated by
pressure transmitter on Manin steam line . The pressure at down stream will be
controlled from pressure transmitter down stream of the dump steam PRDS.
(F)LP steam system for LP heater

From each Steam Turbine Generator extraction at around 2.0 kg/cm2(a) will be
taken for LP heater. This line will be provided with Pneumatic operated quick
closing non-return valve (QCNRV) and motor operated valve.
Suitable drain at low points and vents at high points shall be provided as per the
piping layout. All high pressure (40 ksc (a) and above) drains and vents shall be provided
with manually operated double isolation valves.
8.1.1. CONTROL PHILOSOPHY
Steam Temperature & pressure will be maintained by combustion control loop and
attemperator in the respective boiler. The control range for temperature is 60 – 100 % for
the individual boilers for combined firing of Petcoke & Imported coal (70:30 ratio on heat
value basis). In the event of Load throw-off, the steam pressure will tend to increase
which will activate turbine bypass control valve and excess steam (maximum 25% of
TMCR) will be bypassed to surface condenser. At the same time the combustion control
loop of boiler will also activate and once the same is stabilised turbine bypass system will
close.
8.1.2. LINE SIZING FOR STEAM SYSTEM
Line Description Pr. Temp Flow Pipe Velocity Pr. Drop

Kg/cm2 Deg. kg/hr size m/s. (Kg/cm2)
(a) C mm-
NB
Boiler to Turbine 89 515 76000 200 32.88 2.764

2 x 18 MW CPP
PP 030 M B01 0 1 49
Turbine to HP 21.7 349 7490 100 32.76 0.549

Heater
Turbine to deaerator 5.74 208 5740 150 26.50 0.143
Turbine to LP 2.0 119.7 5980 250 29.44 0.047
Heater
8.2. FEED WATER SYSTEM
The Feed Water System will supply feed water to each Boiler. It will also supply
Feed Water to the PRDS for Deaerator steam and to the attemperators in between the two
stages of super heaters for the 2 boilers.
The feed water system comprises one (1) deaerator-cum-feed water storage tank,
three (3) feed water pumps each of 100% MCR capacity (corresponding to each boiler),
feed control station and feed line from the feed pump suction manifold of deaerator to
Boiler. Details of the Deaerator and Boiler Feed Water Pumps are indicated under Boiler
details.
The deaerator will be common for both Boilers and will supply deaerated feed
water to the Boilers. Necessary piping associated with deaerator will be included.
The deaerator unit will be complete with necessary internal trays, water sprays,
water level control system, and temperature control system, safety valve and vacuum
breaker. The storage tank will be complete with level indicator and alarm, access ladders
and platforms.
Steam for heating will be supplied from the extraction of steam turbine. Provision
will also be made for supply of steam from the Boiler through a system of pressure
reducing valve and utilising flash steam from continuous blow-down tank. The oxygen
content on the outlet water will be not more than 0.007 ppm. Deaerator & storage Tank
will be constructed out of 516 Gr. 70 plates or equivalent. All internals are SS.
8.2.1. FEED WATER HEATERS:
The HP heater will be located on the down stream side of boiler feed pumps and
will be used for raising the boiler feed water temperature to 210oc. The HP heater shall be

2 x 18 MW CPP
PP 030 M B01 0 1 50
mounted horizontally in the turbine house. The heating steam for the HP heater shall be
supplied from the turbine bleed. The condensate drain from the HP heater shall routed into
the deaerator and the emergency drain from the HP heater will be connected to the
Deleted:
condenser through the flash tank. The feed water outlet from each the HP heaters will be
connected to respective boiler economiser through feed water control station. Down stream
line of HP heater is interconnected through isolation valve (normally closed). The feed
waterside of the HP heater shall be designed to withstand the boiler feed pump shut-off
pressure. The steam side of the HP heater shall be designed to suit the highest bleed steam
pressure obtainable.
The LP heater will be located on the down stream side of condensate extraction
pumps and will be used for raising the boiler feed water temperature to 115oc. The LP
heater shall be mounted horizontally in the turbine house. The heating steam for the LP
heater shall be supplied from the turbine bleed. The condensate drain from the LP heater
shall be led into the condenser flash pipe. The feed water outlet from LP heater will be
connected to the deaerator through level control station. Both the HP & LP Heater will be
516 Gr. 70 or equivalent material & the tubes are of SS.
Each main feed control station is provided with one 100 % & one 40% control
valve and a common motorised inching type bypass valve (for 100% flow). The upstream
isolation valves for the control stations are motorised for remote operation.
HP Heater shell side level is maintained by a control station leading the Condensate
to the deaerator. In case of deaerator high level or at low load & starting, this condensate
will be diverted to the Condenser through another control station.
In case of very high level in the shell side, extraction steam line motorised valve
will be closed & the feed water heater is bypassed by means of motorised inlet, outlet &
isolation valves provided for the HP Heater.

2 x 18 MW CPP
PP 030 M B01 0 1 51
8.3. CONDENSATE SYSTEM
The Condensate System will supply condensate from the condenser hotwell to
deaerator. It will also supply sealing water for valves above 2” in size under vacuum
service.
The exhaust steam from the Steam Turbine is condensed in the air- cooled surface
condenser. Drain condensate from LP heater, GSC and inter-after condensers are taken to
the expansion surge pipe of the condenser.
8.3.1. AIR COOLED CONDENSER
The condenser shall condense all the steam at the Turbine exhaust, and shall
receive all the condensate from the steam jet ejector condensers, Gland Steam Condenser
and LP heater. At an emergency condition of very high level in HP heater, the condensate
will be diverted to condenser instead of the deaerator. An expansion surge pipe mounted
near the condenser will receive all the drains. The vent and drain from the expansion pipe
will be connected to the steam exhaust duct and hotwell of the condenser respectively.
The air condenser shall be designed as per Heat Exchanger Institute standard for air
cooled condensers. Several modules of air cooled condenser shall be arranged in banks
side by side.
The air cooled condenser shall be designed for steam exhaust parameters
corresponding to 100% MCR of rated steam flow turbine with 10% margin. The condenser
shall be designed to maintain a pressure of 0.20 Ata, at 42°C ambient temperature at 100%
turbine MCR condition with HP & LP heater online. It shall be ‘A’ frame structure
supporting tube bundles comprising of extruded aluminium finned tubes with CS tubes,
wind and partition walls, staircase, maintenance walkway and doors, etc. The fin height
and pitch of the fins will be selected to have minimum dust accumulation and effectiveness
of the cleaning system. An interconnecting platform will be provided between the STG
building at operating floor to the air cooled condenser.
The fans for the air cooled condenser shall be of GRP material. One of the fan shall
be VFD driven and balance fans shall have dual speed to control the condensing pressure
2 x 18 MW CPP
PP 030 M B01 0 1 52
at part loads and at low ambient temperatures. A semi-automatic fin tube cleaning system
shall be provided. The detail scheme for the same shall be provided later.
The condensate from the steam exhaust duct will be led to the condensate storage
tank (an effort will be made to combine the drain pot required for collecting the condensate
in the exhasut duct and condensate storage tank or the hotwell). The condensate from the
air cooled condenser will be collected in the condensate storage tank. The condensate
storage tank will be sized for 10 minutes storage between the low level and high level. The
condensate tank will be located near the air cooled condenser at an elevation of approx. 4
to 5m so as to provide adequate NPSH for the condensate extraction pumps.
A rupture disc/ Bursting Diaphragm designed as per manufacturer’s standard, shall

be provided on the condenser to prevent over-pressurisation of the condenser.
The following are the brief details of the condenser:
Type : Air cooled condenser with extruded

aluminium finned tubes
Design code : HEI
Service : Continuous
Location : Outdoor
Condenser pressure : 0.2 Ata
Design ambient temperature : 42 °C

Fluid circulated : Exhaust steam from turbine
Design pressure kg/cm2 (a) : 1.26ata & Full vacuum
Design temperature °C : 130 °C
Margin on heat load % : 10% over 100% TMCR condition
Plugging margin : Nil
No. of modules : 6

2 x 18 MW CPP
PP 030 M B01 0 1 53
No of fins per inch : 9
Tube cleaning system : Semi-automatic
Condensate tank capacity : 10.0 minutes storage of the total

design condensate flow at turbine
guarantee condition between normal
level to low level, as per HEI
Material of Construction
Tubes : CS (SA 214)

Header material : IS-2062 Gr. B
Fins : Aluminium
Condensate tank : SA –516 Gr. 70
8.3.2. AIR EVACUATION EQUIPMENT
Non-condensable gases in the cycle water and air ingress in the condenser are
evacuated by steam jet air ejectors to maintain vacuum in the condenser.
The air evacuation system shall be designed as per HEI. The system shall comprise
service air ejectors for normal operation and a Hogger / Start up ejector for initial pulling
of vacuum. The start up ejector shall be used to evacuate air from the Condenser and the
interconnecting piping. The motive fluid for the start up ejector shall be tapped from the
main steam line. The exhaust of the start up ejector is let out to the atmosphere through a
silencer.
After initial vacuum is pulled, the service air ejectors are valved in. The source of
steam for the ejectors is from the downstream of the PRDS tapped from the Main steam
line. During normal operation, only the service ejectors will be in operation. For reliability
2x100% service air ejectors are provided. Each service air ejector is of two stages with an
intercondenser between the Ist and IInd stage and an Aftercondenser located after the IInd
stage. The condensate from the Intercondenser and Aftercondenser is led to the condensate
tank through a loop seal and trap station respectively. Condensate from the CEP discharge
passes through the tube side of the Inter and Aftercondensers. The ejectors will be located
outdoor, on the operating platform of the air-cooled condenser.

2 x 18 MW CPP
PP 030 M B01 0 1 54
The following are the brief details of the Ejectors: -
No. of ejectors : Two (1W+1S)
No. of starting ejector : One
Design Calculations Standard : HEI
Location : Outdoor
Medium to be handled : Mixture of air , steam , and non-

condensable gases
Cooling Medium : Condensate
Material of construction
Body / Diffuser : Carbon Steel
Nozzles : Stainless Steel
Heat Exchanger
Shell : IS 2062
Tubes : Stainless Steel
Tube sheet : IS 2062
8.3.3. CONDENSATE EXTRACTION PUMPS
2 x 100% Condensate Extraction Pumps (CEPs) shall be provided for each air-
cooled condenser and will be located below the condensate tank. Each pump shall be
provided with a suction strainer, a manual operated suction valve and a manual operated
discharge valve. The CEPs shall be provided with gland packing.
The CEPs shall be operated from the plant DCS.
The CEP will start only if the condensate tank level not low.
The pump will trip if:

Condensate tank level is very low.
Motor is overloaded

2 x 18 MW CPP
PP 030 M B01 0 1 55
The standby pump will come on auto if:
Running pump trips

Discharge header pressure drops below a predetermined value as sensed by a
Pressure Switch.
In order to prevent the operation of the CEP on shut off head and to ensure
minimum flow through the Inter/After Condenser, Gland Steam Condenser and LP heater-
a recirculation facility is provided for the CEP. This consists of a control valve CEP
discharge flow transmitter. The recirculation flow is routed back to the condensate tank.
The condensate outlet from the CEP is routed to the common deaerator after
passing through LP heaters. The condensate inlet to each deaerator from the condenser
shall be modulated by a control valve station, located at the outlet of LP Heater.
The following are the sizing details of the Condensate Extraction Pumps:
Quantity / Operating / 2/1/1 Discharge Static Head 22

Standby (per STG) (due to Level
Difference) (mLC)
Service Liquid Condensat Discharge Vessel 5.22
e internal Pressure
(Kg/cm2 a)
Pumping Temp (0C) 57.4 Discharge Line Pressure 5.13
Drop (mLC)
Capacity (m3/hr) 75 Discharge Line Pressure 20
Drop across Eqpt.
(mLC)
Suction Static Head (due 5* (will be Discharge Line Pressure 7
to Level Difference) confirmed Drop across C.V. (mLC)
(mLC) later)
Suction Vessel internal 0.18 Discharge Pressure at 10.63
Pressure (Kg/cm2 a) Pump Outlet (Kg/cm2-a)
Suction Line Pressure 0.25 TDH including margin, 115
Drop (mLC) (mLC)
Suction Pressure at Pump 0.493 Motor Rating (kW) 45
Inlet (Kg/cm2-a)
Vapour Pressure at Pump 1.8 Casing MOC A 216
Inlet Temperature (mLC) WCB
NPSH available (mLC) 3.13 Impeller MOC CA 6NM /
A 351
2 x 18 MW CPP
PP 030 M B01 0 1 56
CF8M /
equi.
Shaft MOC SS 410
Type : Horizontal, centrifugal
No of pumps : 2 (1 W + 1S)
Design code : HIS /BIS
Mode of operation : Continuous
Liquid handled : Condensate
NPSHR : Not greater than 50% of NPSH

available
Drive : Electric motor
Capacity : 75m3/hr Based on condensate

flow HP / LP out condition.
Pump TDH mWC : Deaerator operating pressure +

static pressure + pressure loss
along the condensate discharge
line (including Flow element) +
Pressure drop across Ejector
condenser, gland steam
condenser, LP heater – Suction
pressure (-ve).
8.3.4. MAKE-UP WATER
The normal DM water make up to the power cycle shall account for the loss of
water from the system due to blowdown from the Boilers (considered @1.5% normal &
2.5% maximum), loss of steam from Service Air ejectors, deaerator losses and leakage of
water from the system. Make-up for above losses are provided in deaerator from DM water
storage tanks from DM water transfer pumps through make-up water control station. The
level control station will be controlled from level transmitter provided in deaerator feed
water storage tank. The control valve will be sized for 2.5% of BMCR requirement for

2 x 18 MW CPP
PP 030 M B01 0 1 57
both boilers. A bypass line (sized for 30% of BMCR requirement of single boiler) will be
provided to cater to requirement of initial fill-up and emergency make-up. The make-up
water treatment plant is designed for 5m3.hr i.e. 5m3/hr RO plant followed by a two
stream DM plant, each sized for 5m3/hr capacity.
Power cycle = Make-up Water requirement:
- Boiler blowdown = 2.4 m3/hr (considering 1.5% blowdown)
- Loss of steam from service air ejectors = 0.9 m3/hr
- Deaerator loss (@5%) = 0.2 m3/hr
- Total DM water make-up required = 3.5m3/hr
DM water pH is measured & boosted to about 8.5 before admitting the same to the
cycle.
A modulating type level control valve will be provided in the make up water line to
the Deaerator.
LP heater level is controlled by the LP drain control valve. In the event of very
high level in the LP heater shell side, the extraction steam is automatically closed & the
feed water heater bypassed by means of motorised isolation & bypass valves.
8.4. STEAM AND WATER CHEMISTRY
Feed water analysis at inlet to Economiser

General appearance Clear & colorless
Total Hardness as CaCO3 PPM Commercial zero
Total Fe ppm 0.01
Total Cu ppm 0.05
Dissolved O2 ppm 0.007
Oil & organics ppm NIL

2 x 18 MW CPP
PP 030 M B01 0 1 58
pH value at 25°C 8.5 TO 9.5

Total Dissolved solids ppm 0.01
Silica SiO2 ppm 0.02
Intermittent blow down (once % Once in 8 hours
in 8 hours)
Boiler Water Analysis

pH 10.2 – 10.7
TDS ppm 100
Silica ppm 1.63
PO4 ppm 5 – 12
Alkalinity ppm
Oil & organics ppm 0
9. PLANT WATER SYSTEM

9.1. PLANT WATER SYSTEM
The CPP will receive raw water from the existing clarified water line running
parallel to the CPP boundary wall (existing line at north west of CPP within 400m from the
boundary wall).
The reservoir is sized for 24hrs storage plus dead water required for the fire water
system The raw water required for the CPP is taken by a tapping the existing raw water
line and is stored in an open raw water reservoir. The reservoir will be partly underground
and partly overground, open earth bund type with RCC / geo membrane lining. The
capacity of the reservoir is selected such as to provide 24hrs storage plus 2 hrs dead water
storage for the fire water system.
Make-up water requirement:
Power cycle make-up m3/hr 3.5

2 x 18 MW CPP
PP 030 M B01 0 1 59
Cooling Tower make-up m3/hr 12.75
RO reject m3/hr 1.17
DM Plant regeneration water m3/day 14

requirement
Cooling Tower Side Stream filter m3/day 13

backwash requirement
Total (make-up water requirement) m3/hr 18.54
The make-up water requirement is worked out considering the worst raw water
quality.
Reservoir capacity : make-up water for CT make-up, power cycle make-up &
losses + 2 hrs Dead water storage for fire water requirement
:18.54m3/hr x 24 + (2 x 273 + 40/60 x 100) m3
: 445 +610 = 1055m3.
: margin for surface evaporation : 2% = 20m3
: selected capacity = 1500m3.(considering water required for

future unit no. 3).
The revised design basis now is based on the worst among the Dam water and various borewell water
analysis:
Sl. Parameter Unit of Dam Water Borewell Borewell Borewell Borewell Design
Measure Dhanari No. 1 @ No. 2 @ No. 3 @ No. 4 @ Water
ment Dam at Dhanari Dhanari Dhanari Dhanari Analysis
GDC
A. Physical
Properties:
1 Colour Hazen <5 <5 <5 <5 <5 <5

2 x 18 MW CPP
PP 030 M B01 0 1 60
Units
2 pH at 25°C 8.13 7.7 7.9 7.85 7.65 8.13
3 Total Suspended Mg/l 124 60 72 108 44 140
Solids
4 Oil and grease Ppm Nil Nil Nil Nil Nil Nil
5 Total dissolved Mg/l 64 380 296 256 816 1200
solids
B. Chemical
Properties :
1 Total Hardness Mg/l 116 240 216 228 332 332
as CaCO3
2 P –Alkalinity as Mg/l Nil Nil Nil Nil Nil Nil
CaCO3
3 M- Alkalinity as Mg/l 99 267 232 236 310 310
CaCO3
4 Calcium as Ca Mg/l 21 48 43 48 85 85
5 Magnesium as Mg/l 16 30 26 26 30 30
Mg
6 Sulphate as SO4 Mg/l 1.31 2.62 0.5 1.0 114 114
7 Chloride as Cl Mg/l 21 21 21 21 133 133
8 Nitrate as NO3 Mg/l < .10 < .1 < 0.1 < 0.1 < 0.1 < 0.1
9 Reactive Silica as Mg/l 2.18 15.78 6.10 6.52 3.41 15.78
SiO2
10 Colloidal Silica Mg/l Nil Nil Nil Nil Nil Nil
as SiO2
11 Chemical Mg/l Nil Nil Nil Nil Nil Nil
Oxygen Demand
as O2
12 Biological Mg/l Nil Nil Nil Nil Nil Nil
Oxygen Demand
as O2
13. Iron as Fe Mg/lit .63 < .10 < .18 < .26 < .56 0.63
14. Manganese as Mg/lit <.10 <.10 <.10 <.10 <.10 < 0.1

2 x 18 MW CPP
PP 030 M B01 0 1 61
Mn
15. Copper as Cu Mg/lit <.10 <.10 <.10 <.10 <.10 < 0.1
16. Coliform __ Present Present Present Present Present 18
(MPN/100ml) (18+) (18+) (18+) (18+) (18+)
It is assumed that the concentration of all other parameters is Nil.
Water Treatment System

The RO plant will be designed to generate 5m3/hr permeate with 50ppm TDS considering inlet TDS of
1200ppm. The outlet of the RO plant will be fed to a 5m3/hr, two stream DM plant to obtain boiler
make-up water with 0.2 µmhos/cm conductivity. The DM plant is designed for an inlet TDS of
100ppm. Hence, under normal conditions when the inlet water TDS is less than 100ppm, the RO plant
will be by-passed and the DM plant alone will be in operation. The DM Plant may still be used with
inlet TDS higher than 100ppm (up to 250ppm) with lower hrs of operation between regeneration.
Whenever the inlet water TDS is higher (> 250 ppm), the raw water will be fed to the RO plant
followed DM plant to obtain boiler make-up water.
The cooling tower make-up water will be taken from the clarified water storage tank. Under the worst
condition i.e. with borewell water alkalinity of 310ppm, a COC of 2.8 can be maintained with
72kgs/day sulphuric acid dosing in the cooling tower basin. The extent of acid dosing will be depend
on the alkalinity level in the clarified water. The cooling tower make-up will be 13m3/hr.
With this configuration, the water treatment plant can handle Dam water as well as water
from the various borewells. The power plant operator has the liberty to choose either the DM
plant or {RO + DM} plant based on the inlet raw water analysis.
a) Cooling Tower Makeup Scheme
A softener will be provided for the cooling water make-up water to reduce the hardness in
the raw water to less than 5ppm. 2 nos. 25m3/hr Filtered water transfer pumps shall feed
the 1 x 20m3/hr softener. The cooling tower will be designed with a COC of 3 so as to
maintain the circulating cooling water concentration below 1000ppm. The filtered water
from the filtration plant will be stored in 1 x 150m3 soft water storage tank. 2 x 12m3/hr
(1W+1S) Cooling water make-up pump will be provided, which will supply the water
through a level control station for the Cooling Water Makeup requirement
b) Power Cycle Make up Scheme

2 x 18 MW CPP
PP 030 M B01 0 1 62
The filtered water from the filtration plant will be fed to the DM plant. The treated
water will be stored in 2 x 120m3 DM water storage tanks.
9.2. COOLING WATER SYSTEM
9.2.1. PROCESS DESCRIPTION
The Cooling Water System is provided for removing the heat from the Turbine lube
oil coolers, generator air coolers, air compressors, boiler feed water pumps and boiler
sample coolers dissipates it in the Cooling Tower.
The cooling tower will be of mechanical, induced draft, multi cell, cross-flow type.
The construction of the cooling tower will be of FRP with RCC sump and forebay. It shall
consist of three cells (2working + 1 standby) and shall cool the hot return water and
discharge it into an RCC fore bay. The tower will be designed in such a way that any cell
can be operated, repaired or maintained independent of the other cells. Each cell outlet will
have a coarse and fine screen for filtering out any air borne debris. The make up water will
be added in the cooling tower basin and will be suitably treated to prevent biological
growth, corrosion and scaling. Side stream filtration plant will be sized for circulating
water (5% circulation flow). Drains from the sumps located behind the Towers shall be
provided for each cell which shall be routed to effluent pit.
The cold water shall be pumped by Cooling Water pumps (2 x 100%) of

horizontal, centrifugal type. These pumps shall take suction from the cooling tower fore
bay. Make-up water to the cooling tower shall be done in the fore bay through a level
control station. The cooling water shall be circulated through independent piping.
Manual isolation valves shall be provided at the discharge of the pumps Manual
isolation valves are provided in the return line inlet to individual cells of cooling tower. A
pneumatically operated control valve is provided in the CT makeup water line to regulate
inflow based on level in the cooling water sump. Drain valves are provided between the
cooling water pump and discharge isolation valve.

2 x 18 MW CPP
PP 030 M B01 0 1 63
Circulating Cooling Water is liable to pick up air borne dust. Continuous filtration
of a part of the circulating water in a side stream filtration system is provided to limit the
suspended solids.
The side stream filtration unit comprises two numbers Filters. The cooling water
return flow passes through the side stream filter before joining the return header leading to
cooling tower.
Backwash of the filters is performed by reverse flow of the inlet water along with
air scouring. The effluent from the filters is routed to the Effluent Pit. A common blower
shall provide air for scouring to both filters.
The Cooling Water System (ACW) circulates cooling water through STG lube oil
cooler, generator air coolers, air compressor coolers, Boiler sample coolers and HVAC
system and makeup to the air washer units.
The cooling water system consisting of 2 x 100% cooling water pumps will
circulate the cooling water through the equipment mentioned above for heat pickup and
through the cooling tower for subsequent cooling.
9.2.2. SYSTEM SIZING CALCULATION
The following criteria are considered for the Cooling Water System Sizing.
Cooling water inlet temperature to condenser is 33°C
Cooling water outlet temperature from condenser is limited to 42°C
Calculation for Cooling Water Flow:
Auxiliary Cooling Water Flow requirement break up:

Requirement (m3/hr)
ST Generator air cooler : 276
STG lube oil cooler : 88
Sample coolers : 20
BFP coolers : 10
Air compressors coolers (Including Ash Handling : 40

2 x 18 MW CPP
PP 030 M B01 0 1 64
Compressors)
A/ C system : 30
Air washer : 10
Total : 474
TOTAL CIRCULATING WATER REQUIREMENT = 474 + 5%MARGIN =497.7 M3/HR
Cooling tower selected = 500 m3/hr
COOLING TOWER SIZING
The Cooling Tower has been sized with 3 cells of 250 m3/hr capacity each. The
range of the Tower is specified as 9-deg C.
Summary of Cooling Tower Technical Parameters
1 Type : Mechanical Induced Draft Cross Flow

2 Construction : FRP
3 No. of cells : Three (2W + 1S)
4 Flow rate : 250 m3/hr per cell
5 Design wet bulb temperature : 280C
6 Cold water temperature : 33 °C
7 Range : 9 °C
8 Water quality : Circulating water
9 Cycles of Concentration : 2.8 Deleted: 3
10 Drift loss (max.) : 0.05% Formatted: Body
Cooling Tower Make-up Requirement:
Evaporation loss m3/hr 8.0
Blowdown loss m3/hr 4.5
Drift loass m3/hr 0.25
Cooling Tower make-up m3/hr 12.75

requirement

2 x 18 MW CPP
PP 030 M B01 0 1 65
SIDE STREAM FILTER SIZING
The side-stream filters are designed for auxiliary cooling water flow rate which
corresponds to about 5% of total Cooling Water flow rate.
Other details of the side stream filter as
Quantity / Operating / 1 Type of Tank Cylindrical,

Standby Horizontal
Service Liquid Circulating Water
Temp (0C) 33 Height Later
Operating Pressure (Kg/cm2- 2.2 MOC: Shell IS 2062
g) Dish
PUMP SIZING
♦Auxiliary Cooling Water Pump
Quantity / Operating / 2/1/1 Discharge Static Head 7.5

Standby (mLC)
Service Liquid CW Discharge Vessel internal 0
Pressure (Kg/cm2)
Pumping Temp (0C) 33 Discharge Line Pressure 10
Drop (mLC)
Capacity (m3/hr) 550 Discharge Line Pressure 10
Drop across Eqpt. (mLC)
Suction Static Head (due to 0 Discharge Line Pressure 0
Level Difference) (mLC) Drop across C.V. (mLC)
Suction Vessel internal 0
Pressure (Kg/cm2)
Suction Line Pressure Drop 0.58 TDH including 10 % 30
(mLC) margin, rounded (mLC)
Suction Pressure at Pump 1.003 Motor Rating (kW) 60
Inlet (Kg/cm2-a)
Vapour Pressure at Pump 0.45 Casing MOC CI
Inlet Temperature (mLC)
NPSH available (mLC) 9.0 Impeller MOC CI
Shaft MOC C40

2 x 18 MW CPP
PP 030 M B01 0 1 66
9.3. SERVICE & DRINKING WATER SYSTEM
9.3.1. DESCRIPTION
The total service & drinking water consumption is about 0.4 m3/hr, as detailed in
the calculation for pump sizing below (considering a maximum possible staff of 60). The
Tank size is considered 1 m3, which would be adequate for about 21/2-hrs storage.
Hpochlorite dosing is already done upstream of the filteration plant.
9.3.2. SYSTEM SIZING CALCULATION
The following calculation indicates the service / potable water consumption details.
1 Consumption per day per person (Estimate) Liters 150.0
2 No. of persons considered in STG Bldg / Admin Nos. 60
Bldg
3 Total Potable & Service Water Consumption per day M3 9
4 Total Potable & Service Water Consumption / hr M3 / hr 0.4
3
5 Total Potable & Service Water Consumption M / hr 1.0
considered
10. FUEL & LIME STONE HANDLING SYSTEM

The boiler will adopt atmospheric fluidised bed combustion system and the fuel
firing system will be designed for `under bed feeding’ system. The fluidised bed will
consist of five (5) compartments and each section will be provided with fuel feeding
nozzles and adequate number of stainless steel fluidising air nozzles fitted out to the
distributor plate.
The boiler will be operated on the following fuel combination.
Case1: 100% Imported coal
Case2 : 100% Indian coal
Case 3: Pet Coke70% / Imported / Indian Coal30% (on heat value basis)
10.1.ANALYSIS OF COAL & COAL CONSUMPTION

2 x 18 MW CPP
PP 030 M B01 0 1 67
10.1.1. FUEL SIEVE ANALYSIS , ULTIMATE AND CHEMICAL ANALYSIS
FUEL ANALYSIS
1. - SIEVE ANALYSIS OF SOUTH AFRICAN COAL
NO. OF SAMPLES : 6
SL. NO. SIEVE SIZE MIN (%) MAX. (%)
1 25.0 MM 5+2 8+2

2 16.0 MM 12+2 14+2
3 12.5 MM 8+2 10+2
4 6.5 MM 20+2 24+2
5 4.6 MM 7+2 10+2
6 2.0 MM 4+2 7+2
7 1.O MM 15+2 18+2
8 - 1.0 MM 8+2 10+2
2. – SIEVE ANALYSIS OF PET-COKE
NO. OF SAMPLES : 5
SL. NO. SIEVE SIZE MIN (%) MAX. (%)
1 25.00 MM 4+2 7+2

2 16.00 MM 5+2 8+2
3 12.50 MM 4+2 6+2
4 6.50 MM 11+2 13+2
5 4.60 MM 4+2 7+2
6 2.00 MM 14+2 16+2
7 1.O0 MM 42+2 50+2
8 (-) 1.00 MM 6+2 8+2
3. - SIEVE ANALYSIS OF CRUSHED LIME-STONE
SL. NO. SIEVE SIZE PERCENTAGE ( % )
1 100 MM NIL

2 x 18 MW CPP
PP 030 M B01 0 1 68
2 80 MM 5+2
3 40 MM 25+2
4 20 MM 30+2
5 (-) 20 MM 40+2

2 x 18 MW CPP
PP 030 M B01 0 1 69
TYPICAL CHEMICAL ANALYSIS
LIME- SOUTH AFRICAL

PERAMETER % STONE PET-COKE COAL
(COAL ASH) (COAL ASH)
LOI % 35+ 0.2

SiO2 % 12.8+ 0.2 20.7 39.6
Al2O3 % 3.6+ 0.1 35.8 38.2
FE2O3 % 2.0+ 0.1 8.4 4.5
CaO % 42.4+ 0.2 15.2 4.6
MgO % 1.4+ 0.1 2.1 0.8
Na2O % 0.2+ 0.05 1.3 0.18
K2 O % 0.5+ 0.05 0.62 0.6
SO3 % 0.2+ 0.05 14.4 3.3
TiO2 % TRACESS 1.41 1.7
P2O5 % NIL 0.12 0.8
PROXIMATE ANALYSIS
IM % 1.0+ 0.5 3.0+ 0.2

VM % 9.0+ 1.0 26+ 2.0
ASH % 1.5+ 0.5 16+1.0
FIX CARBON % 90+ 1.0 60+ 1.0
GROSS CV (ON DRY BASIS) 8000+100 6250+100
ULTIMATE ANALYSIS
CARBON % 87+ 2.0 66+ 1.0

HYDROGEN % 3.5+ 0.5 4.5+ 0.5
NITROGEN % 0.8+ 0.2 0.5+ 0.1
SULPHER % 6.6+ 0.4 0.9+ 0.2
MINERAL MATTER % 0.3+ 0.1 15+ 1.0
OXYGEN BY DIFF. % 0.6+ 0.1 11.5+1.0
H.G. INDEX 49+ 2.0 58+ 2.0

2 x 18 MW CPP
PP 030 M B01 0 1 70
INDIAN COAL
ULTIMATE ANALYSIS
%
11. CONSTITUENT
Carbon 34.2
Hydrogen 2.75
Nitrogen 2.5
Sulphur 0.5
Oxygen 7.05
Ash 45
Moisture 8
G.C.V. (kcal/kg) 3400
As the sieve analysis for indian coal is not available, it has been assumed that the coal size is
less than 75mm size (as indicated during the pre-order stage).
11.1.SYSTEM SIZING
11.1.1. FUEL HANDLING SYSTEM SIZING
To arrive at the Coal Handling system sizing, the coal consumption per Boiler is
calculated as indicated in the table below. Please also refer to attached Heat & Mass
Balance Diagram.
Case 1 Case 2 Case 3
Description 70% Pet Coke 100% 100% Indian
+ 30% Imported coal coal
Imported Coal
Fuel Flow (Kg/hr) 7895 9027 16172
per Boiler
Fuel Flow (Kg/hr) 15790 18054 32344
for 2 Boilers
Coal Handling 31580 36108 64688
system flow rate
considering 12
hours operation
per day (Kg/hr)
Selected 65,000
Capacity, (Kg/hr)
Note: Above Coal Consumption are calculated based on 77.00 TPH Steam
Generation from each boiler.
2 x 18 MW CPP
PP 030 M B01 0 1 71
11.1.2. LIME HANDLING SYSTEM SIZING
To arrive at the Coal Handling system sizing, the coal consumption per Boiler is
calculated as indicated in the table below. Please also refer to attached Heat & Mass
Balance Diagram.
Limestone flow rate per Boiler = 4882 kg/Hr
Hours of Operation per day = 5 hours
Required Capacity of handling system = 4882*2*24/5
= 46867 Kg/hr
Capacity provided, with margin = 50 TPH
Each boiler will be provided with fuel bunkers.
Fuel bunker holding capacityhas been decided on 16 hrs storage basis.
Bunker sizing basis is discussed in section 7 of this document.
The fuel handling system capacity is selected as 65TPH, which under normal
operation i.e. with 70% petcoke and 30% imported coal will work for less than12hrs per
day. The handling system consists of a 60TPH truck tippler (with a payload capacity of
35T), which unloads the fuel into a 35T ground level grizzly hopper. An emergency
ground hopper of 20T is provided next to the 35T hopper, to be used whenever the truck
tippler is not available due to maintenance. Pay loaders will be used for loading the fuel
into the emergency hopper. Vibrating feeders are provided under each of the grizzly
hoppers, which will convey the coal to screen house. As the % fines is quite high, the
conveying system is arranged in such a manner that the vibrating screens will screen the
material prior to loading in to the crushers (refer to the attached coal handling flow
scheme) thus serving the purpose of both primary screen and final screen. The oversize
fuel (+6mm size) will be fed to the crusher and crushed fuel is recycled back to the
vibrating screens. No covered shed is envisaged over the truck tipper and grizzly hoppers.
Dust suppression system will be provided over the grizzly hopper, to suppress the dust
during fuel loading to 35T grizzly hopper. 2 x 100% dust suppression pumps will be
provided near the effluent pit, with pneumatic ON/OFF valve for control of the
suppression system at the tippler area.

2 x 18 MW CPP
PP 030 M B01 0 1 72
2 x 100% impactor type crushers will be provided, each capable of crushing fuel
and limestone. A divertor chute will be provided upstream of the crushers to enable
selection of either of the crushers. For a 65TPH screen, the width of the screen are not
large and feeding to screen through belt conveyor will not affect their performance. As
vibrating feeders will be provided under the grizzly hoppers for controlled feeding,
possibility of surge in the system is not envisaged. Hence surge hoppers upstream of the
crusher is not considered.
1 no. Flip-flop type screen will be provided for screening fuel and cirular motion
screen limestone. The screened fuel (product –6mm size) will be fed to the product
conveyor.
The product conveyor will carry the material to Boilers and will feed to a travelling
tripper in the transfer tower near boiler bunker area. Drag chain conveyor will be provided
on the respective bunker for feeding each of the bunkers through multiple opening. Each
opening will be provided with pnuematic / motor operated gate arrangement. The
travelling tripper will feed material to each of these Drag chain conveyor. The conveying
system will cater to handling of fuel, limestone and bed material. Only one type of fuel
will be handled at a time.
Dust extraction systems will be provided for coal storage bin, screens and crushers and
other dust generation points. Dust Extraction system for material handling plant will
ensure minimum leakage. Dust Extraction system bag filter outlet will be designed for 50
mg/nm3 SPM level.
Ventilation system will be provided for all the boiler bunkers.
Inclination of conveyors will be restricted to 16° to horizontal. However, inclination of

conveyor from hopper feeding (where inclined feeding of martial is required due to lay-
out constrain) conveyor angle will be restricted to 15°.
Speed of belt conveyor shall be 1.3 m / s (max).
Walk way (Grating) will be provided on both sides of belt, 750mm width on one side and
500mm on other side.
Coal handling plant will be designed considering open gallery arrangement.

2 x 18 MW CPP
PP 030 M B01 0 1 73
Belt sealing system shall be provided for bunker opening.
In-line belt weigher will be provided on the product conveyor.
All hoppers shall have min. thickness of 6 mm with 10 mm thick sail hard/ equivalent
liner.
Drag chain feeders feeding to the boiler bunkers will have UHMW polymer liner to
prevent wear.
Valley angle of chute and hoppers will be minimum 60°.
Trough angle for conveyor will be 35°.
Skirt for belt conveyor shall be segmented type.
External scrapper for belt conveyor shall be sprung type.
Pull chord switch will be provided at spacing of 12 m.
Belt sway switch will be provided at spacing of 14m.
Belt will be nylon M24 with 5mm top cover and belt velocity will be 1m/sec.
Bag filters for the dust extraction system for bunker area to be anti-static, polyester needle
wire impregnated (duly earthed).
Hoists will be provided for crusher and screen house. Monorails of adequate capacity will
be provided at other locations.
Screen cloth shall be polyurethane.
Air to cloth ratio for Dust Extraction system shall be 1.5 m3/min/m2 (max).
Exhaust of dust extraction system shall be at least 3 m above nearest operating floor level.
The fuel handling system will be controlled from DCS.
11.2.HSD SYSTEM
For boiler start-up, HSD will be used and requirement of HSD is approximately
800 lit/hr/boiler (during boiler start-up). A HSD tank of 15 kL capacity (equal to one
tanker capacity) common for both boilers with common oil pumping unit will be provided.

2 x 18 MW CPP
PP 030 M B01 0 1 74
A common unloading cum forwarding pump will be provided with a provision for
changeover.
11.3.SYSTEM DESCRIPTION
The ash handling system for the two-(2) nos. AFBC boilers, fed by imported coal /
indian coal, petcoke, shall be designed considering continuous operation of the boilers at
MCR.
The boiler will be operated on the fuel combination described under Coal Handling
System (Clause no 10)
The ash handling system basically consists of two schemes:
• Bed ash-handling system, which consists of pneumatic bed ash removal from the
bed ash coolers of boilers. (2 points per boiler)
• Fly ash handling system consists of pneumatic fly ash removal from the air heater,
boiler economizer bank, ESP hoppers. (5 points per boiler)
Bed Ash from both the boilers will be fed into a common Silo. Fly Ash from both
the Boilers will be fed into two silos.
Bag filter for all the silos will be provided with automatic reverse pulse jet cleaning
facility.
The ash disposal from the bed ash silo will be by means of dust conditioner. Ash
from the silos will be discharged into trucks through ash conditioner. One spare connection
with a knife gate valve will be provided on bed ash silo for emergency unloading of ash.
For disposal of fly ash from the silos, both dry type with telescopic chute and wet
type with dust conditioner will be provided.
. Water from the dust suppression pumps ( described in the fuel handling section
above) will be provided for dust conditioning.

2 x 18 MW CPP
PP 030 M B01 0 1 75
Two (2) nos. of fluidising air blowers of adequate capacity (1 W / 1S) to provide
fluidisation in ESP hoppers of both boilers and in the two fly ash silos will be provided.
Requirement of compressed air for dense phase ash handling system shall be met
by two nos. (2x100%) dedicated reciprocating air compressors.
Details of each Ash Handling System are described below.
11.3.1. BED ASH CONVEYING SYSTEM
Bed ash from the boilers will be discharged through the bed ash coolers at about
o
200 C. Each boiler will have a fluidised bed with 4 beds. The 2 bed coolers (2 bed out let
will be connected to one cooler) will be in two rows. Ash from each bed ash cooler outlet
will be collected in MS water cooled hoppers, which shall have grid for separating higher
size particles. These hoppers will discharge ash into ash vessel and ash will then conveyed
pneumatically into the common ash silo.
11.3.2. FLY ASH CONVEYING SYSTEM
Dense phase pneumatic handling system shall be used for conveying the fly ash
from the boiler bank, economizer air preheater and ESP to the two fly ash silos.
i)Boiler connection bank ash
ii) Economiser/APH ash.
Below each hopper outlet at connection bank, economizer and air preheater,
suitable MS surge chutes with 1 no. expansion joint shall be provided. Level probes will be
provided in the surge hoppers for automatic operation of the system. The ash vessel
(transporter) will be placed below each surge hopper. The level probe in the hopper senses
the pressure of material to initiate the conveying cycle. Dome valve will open and allow
the material to gravitate in to the vessel till it is closed automatically by the timer present
as per process parameters. On closure of dome valve, butterfly valve seal gets inflated and
signals the conveying air injection into the transporter.

2 x 18 MW CPP
PP 030 M B01 0 1 76
Material will be conveyed through conveying pipelines pneumatically upto the fly
ash silo.
ii)ESP Ash
Below each ESP hopper outlet provided with Fluidising pads, similar arrangement
as detailed above will be provided. For ESP 1st & 2nd field, hoppers will have identical
capacity ash transporters and the third field will have a transporter of smaller capacity.
Ash will be conveyed pneumatically to the silo & discharged through terminal box.
11.4.SYSTEM SIZING
11.4.1. BED & FLY ASH HANDLING SYSTEM
Bed ash handling System
The ash handling system is designed considering 100% indian coal firing. Total
Bed ash collected per boiler :1300 kg /hr
Note : This value is arrived considering the worst condition i.e.Iindian coal. Also,
this is to be noted that above ash generation is arrived after providing suitable margin
over actual ash generation. Hence, actual ash generation quantity will be less than above.
Number of bed ash collection ports per boiler is 4.
Selected Design bed ash handling capacity per boiler : 2000 kg/hr.
Capacity of common bed ash silo considering 24hrs storage with 600kg/m3 density
= 2 x 1300x 24/600 = 104m3.
Selected capacity = 110m3.
Fly ash handling System
The estimated fly ash generation is 6840 kg/hr. The break-up of the ash collection
at different hoppers will be provided later.
a) Boiler bank hopper : - kg/hr

2 x 18 MW CPP
PP 030 M B01 0 1 77
b) Economiser & APH hopper : - kg/hr
c) ESP hoppers (3nos) : - kg/hr
Hence, Total Fly ash collected per boiler :(a + b + c = )6840 kg /hr
Note : These value are arrived considering the worst condition i.e. 100% Indian
Coal firing. Also, this is to be noted that above ash generation is arrived after providing
suitable margin over actual ash generation. Hence, actual ash generation quantity will be
less than above
However, Selected Design Fly ash handling system per boiler : 7000 kg /hr (per
boiler)
Capacity of fly ash silo considering 24hrs storage with 600kg/m3 density = 1 x
6300x 24/600 = 273.6m3.
Selected capacity = 275m3.
12. COMPRESSED AIR SYSTEM

12.1.PROCESS DESCRIPTION
The CPP will require instrument air for operation of I/P converters, purge
instruments, pneumatic actuation of control valves, dampers, etc. for different systems.
Service air will be required for cleaning of filters, strainers and other general purposes.
Compressed air system, as detailed in this report, is envisaged to supply both service and
instrument air of required quality and quantity.
Instrument air is required for ash handling plant also.
12.2.SYSTEM SIZING
The instrument and service air requirements are listed as below, for arriving at the
system sizing:
12.2.1. INSTRUMENT AIR REQUIREMENTS

2 x 18 MW CPP
PP 030 M B01 0 1 78
STG for 2 units 70 Nm3/hr
Boiler for 2 units 100 Nm3/hr
Ash Handling Plant 80 Nm3/hr
Balance of plant (including DM Plant) 20 Nm3/hr
Total 270 Nm3/hr
Considering spare & leakage losses @ 10% 27 Nm3/hr
Total Instrument Air requirement 297 Nm3/hr
Say 300 Nm3/hr
12.2.2. SERVICE AIR REQUIREMENTS
a) Service air requirement for various service air stations
Area No. of Tap off points

STG building area 2
Boiler 2
DM plant area 1
Ash Handling area 1
Cooling Tower area 1
HSD tank area 1
Misc. 2
Total 10
Ten (10) tapping points have been considered for various applications of service air
for the entire plant. Assuming 20% of the tappings will be in operation simultaneously and
considering 0.6 Nm3 / min. / tapping, the total service air requirements works out to 72
Nm3/hr. Considering spare and leakage losses at 15%, the total service air quantity
required for service air stations work out to 83 Nm3/hr.
b) Service air requirement for coal handling system – 60 Nm3/hr
Total service air required = (83+60) Nm3/hr = 143 Nm3/hr
12.2.3. COMPRESSOR SIZING
Design dry bulb temp : 38.0°C

2 x 18 MW CPP
PP 030 M B01 0 1 79
Design relative humidity : 60 % RH
The Compressor size is arrived at, by means of the following calculation

a) Instrument air : 300 Nm3/hr
requirement
b) 15% additional capacity : 45 Nm3/hr

of instrument air to meet
purge air requirements
of air dryer
c) Service air requirement : 143 Nm3/hr
d) Total (Sum of (a), (b) & (c) : 488 Nm3/hr
Considering 10% margin : 536 Nm3/hr Say 550 Nm3/hr
e) Actual margin available for

loader / unloader function : (550-(300+45))/550 x 100 = 28.1%
considering service air
requirement is occasional and 1
not continuous.
Two (2) nos. (1W + 1S) ono-lubricated reciprocating type air compressors are
considered each with a capacity of 550 Nm3/hr. The compressor discharge pressure will be
8.0 kg/cm2(g). The cooling water available at the inlet of the Coolers is at 330C.
Individual discharges of the compressors are connected to a common discharge

header which in-turn is connected to a main air receiver. This will serve as service air
receiver and will be of 5-m3 capacity.
From the main air receiver a portion of the air quantity is taken to air drier
(1x100%) of 300 Nm3/hr to obtain Instrument Air quality. One tapping is taken to the
service air distribution system. An instrument air receiver of 5-m3 capacity is provided at
the downstream of air dryer for the storage of dry air. From the air receivers, distribution
for instrument and service air is effected. The quality of instrument air at the outlet of
instrument air receiver shall conform to ISA S7.3 standard (-400C dew point at
atmospheric pressure). A manual bypass valve across the drier is provided to use the
service air for instruments in case of an emergency.

2 x 18 MW CPP
PP 030 M B01 0 1 80
Other Technical parameters of the compressor
Compressor capacity : 550 Nm3/hr
Compressor discharge pressure : 8.0 ksc (g)
Number : Two (2) – Two working and One standby
Type : Non-lubricated reciprocating type

compressors
Inter-cooler & after cooler : As per Air Compressor vendor’s standard

and Good Engineering practices.
Control panel : Provided with gauges, annunciation points,

start-stop push buttons, lamp timers with
controls for automatic load/unload.
Air Driers
Type : Heatless purge type, twin tower
No. : 1 X 100% (with twin towers, 100%

capacity
Each)
Output capacity : 300 Nm3/hr
Pre-filters : 2
After filters (Fine filters) : 2
Atmospheric dew point at

drier outlet : -40°C
Pressure at instrument air

receiver outlet : Not less than 7.0 ksc (g)
Design code for Tower vessels : IS 2825
Operation of dryer involves a twin tower filled with a moisture absorbing material
such as activated silica gel, out of which one is working while other is regenerating
alternatively. Drier is located downstream of the service receiver. Compressed air flows

2 x 18 MW CPP
PP 030 M B01 0 1 81
through the working tower, and as it emerges out of it the moisture is absorbed by
absorbent, which in turn gets moist during operation. Subsequently the absorbent has to be
regenerated, as it can no longer dry air efficiently. Now the other tower comes into action
and wet air is passed through it. As it emerges out, part of it (dry air) is used to regenerate
the other cell, while remaining part is passed to the receiver. This process continues in
cycles and the switch over from working mode to regenerating mode is achieved by means
of solenoid valves and timer.
Air Receivers
The details of the air receivers are as follows:
Main Air Receiver (Compressor Area)
1 Design standard : IS 7398 / IS 2825

2 Type : Vertical, Cylindrical
3 No. of units : 1 x 100%
4 Working pressure : 8.0 kg/cm2(g)
5 Design pressure : 1.25 times working pressure
6 Hydrostatic test pressure : 1.5 times design pressure
7. Capacity : 5 m3
8 Minimum shell thickness : 6 mm
9 Material of construction : IS 2062
Shell
Dished End
11 Tolerance/ allowance : 1.5 mm corrosion allowance, 10%
Thinning tolerance for dished ends
Instrument Air Receiver
1 Design standard : IS 7398 / IS 2825

2 Type : Vertical, Cylindrical
3 No. of units : 1 x 100%
4 Working pressure : 7.0 kg/cm2(g)
5 Design pressure : 1.25 times working pressure
6 Hydrostatic test pressure : 1.5 times design pressure
7. Capacity : 5 m3
8 Minimum shell thickness : 6 mm
Shell
Dished End
2 x 18 MW CPP
PP 030 M B01 0 1 82
12 Tolerance/ allowance : 1.5 mm corrosion allowance, 10%

Thinning tolerance for dished ends
The air receivers will be provided with relief valve, trap station and necessary
instruments.
12.2.4. LINE SIZING
Plant service and Instrument air header will each be 40 mm NB considering the
flow rate indicated in the above clauses.
13. AIR CONDITIONING & VENTILATION SYSTEM

13.1.SYSTEM DESCRIPTION
Air conditioning is considered for the following areas of the CPP:

- Central Control Room, Electronic Cubical & office area in the STG building.
- ESP Control room and Chemical Lab of WT Plant,
The Air-conditioning system provided for each area will ensure the specified inside
conditions throughout the year, under all climatic conditions in that area.
Water cooled Package type air-conditioning (PAC) units will be adopted for main
control room and split type air cooled window air conditioners will be provided for other
Air Conditioned Area.
All air-conditioned areas shall be supplied with filtered air.
The main Control Room will be fitted with supply air ducting and return air will
enter in the false ceilings through return air grilles having volume control dampers. The
area between false ceiling and RCC slabs above will be treated as a plenum which shall be
connected to AC plant room.
Supply air from packaged units is routed via the fine filters, and strips heater banks
through sheet metal ducting to the areas to be air-conditioned. Return air is collected over
the false ceiling, provided in the air-conditioned areas to enable routing of return air back
to the plant room. The return air is drawn over the pre-filter and cooling coil of packaged

2 x 18 MW CPP
PP 030 M B01 0 1 83
units by dehumidified air blowers and discharged to the supply air system to complete the
loop. Fresh air is drawn into this plant room at a pre-determined rate.
Package units are complete with compressor, evaporator, expansion coil, &
condenser.
Each PAC unit will have minimum 2 Nos compressors of reciprocating type, semi-
hermetic design with capacity control by automatic ON/OFF of one Or more compressors.
The compressors are designed to assure reliable, trouble free operation and long unit life.
The compressor wear is minimised by the positive pressure lubrication provided with an
automatic reversible oil pump and a built in pressure regulator.
Each PAC unit is fitted with one shell & tube condenser incorporating water cooled
type integrally bonded copper tubes and easily removable cast iron end covers to aid tube
cleaning. The shell casing is formed from MS plate fusion welded.
Each refrigerant circuit has all necessary stop valves, strainer, drier and sight glass,
thermostatic expansion valve, evacuating & charging valve. All suction lines will be
insulated with close fitting cellular insulation.
The air-handling fan will be centrifugal type with forward curved blade, complete
with drive, etc.
The Filters are of synthetic construction and filter the return air before it is drawn
into the cooling coils.
The metal air ducts will be made of galvanised steel sheets. The ducts will be
suitably supported with MS rods, angles, etc to be attached to building fabric. All ducting
will be sized to have uniform friction drop per unit length. Canvas or flexible connection
will be provided at each connection between duct work and fan units to isolate vibration.
All main ductwork will be accessible throughout using fitted hinged access doors.

2 x 18 MW CPP
PP 030 M B01 0 1 84
All supply air grilles have adjustable louvers for desired spread and throw
requirements. Splitter damper in the branch take-off are provided. Fire dampers are
provided at vulnerable locations.
Window Air Conditioners will be provided in other small control panel rooms. TR
requirement of such areas will be decided during further detailed Engineering.
The air conditioning systems will be designed conforming to following codes and
standards.
IS:669 :Safety code for air conditioning
IS:660:Safety code for mechanical refrigeration
IS :277 : G I Sheets [ CL - VIII]
IS : 655 : Metal Air Duct
Ventilation is considered for following areas:
All the buildings or rooms in which waste heat occurs and which has to be removed
but where temperature ranges do not necessitate air conditioning, such as the switchgear
room, STG machine hall, cable spreader room and Air Compressor room.
All the buildings or rooms in which hazardous fumes or vapours are present and have to be
removed but where temperature ranges do not necessitate air conditioning such as the
battery room etc.
All toilets provided with exhaust fans only. Fresh air will enter through louvered doors.
The Turbine Hall, Electrical bay of the STG building consisting of switchgear
room, MCC and cable spreader room shall be provided with wet type pressurised
ventilation system. To cater to the ventilation load of the rooms, four Air washers shall be
provided (2 for the turbine hall Area and 2 for cable cellar & switchgear room).
Ventilation air for TG hall will be augmented by the exhaust from cable spreader
room and switchgear room, which will be routed to the ground floor of TG hall. This air

2 x 18 MW CPP
PP 030 M B01 0 1 85
will rise up to the STG hall through floor openings. This exhaust air will also provide
ventilation in the Condenser Hall.
The wet pressurised ventilation system (evaporative cooling) shall be designed

based on an optimum saturation efficiency of air washer. Air quantity shall be selected in
such a way so as to maintain an inside temperature of 42 deg C during peak summer or a
minimum air change rate of 7-8 per hours whichever is higher.
Compressor room will be provided with Dry type ventilation by providing wall
mounted exhaust air fans.
Ventilation system will be designed by standard Industrial practice and as per

guidelines of Association of Ventilation Engineers, India and American Council of
Government Industrial Hygienics.
13.2.SYSTEM SIZING
Both the Air conditioning and ventilation systems shall be designed for the
following outdoor condition.
Summer
Dry bulb temperature : 46.0°C
Wet bulb temperature : 28.0°C
Monsoon
Dry bulb temperature : 39°C
Welt bulb temperature : 27°C
Winter
Dry bulb temperature : 34°C
Wet bulb temperature : 20°C
The following shall be the indoor conditions:

Air Conditioning System
Main control room : DBT – 24 ±1°C & 50 ±5% RH
Ventilation System
Turbine hall : Below 42 deg C during peak summer.
2 x 18 MW CPP
PP 030 M B01 0 1 86
Switchgear room : Below 42 deg C during peak summer

Cable spreader room : Below 42 deg C during peak summer
Other rooms : Maximum 3 deg C above ambient
Heat Loads
The heat loads considered for estimating the refrigerant capacity of the AC plant
are:
• Solar heat load (sensible and latent)
• Heat gain through walls, doors and windows.
• Equipment load and lighting loads
• Human occupancy load
• Heat load due to fresh air addition in the system.
The following guidelines will be considered while sizing the components of the air-
conditioning system.
• Fresh air supply
1.5 air changes per hour or 0.42 m3/min of fresh air per person, whichever is
higher will be adopted as per the recommended practice.
• Duct/Pipe line sizing
i) Velocity of air at any part in duct shall not exceed 9.0m/sec for A/C
System & 12 m/s for Ventilation System.
ii) Velocity of refrigerant in pipe will be limited to maximum 0.5m/sec,
iii) Velocity of cooling water line to be limited to 1.5m/s for sizes upto 50 NB
& 2.0m/sec. for pipe sizes 50 NB & above.
Air Conditioning Load & Equipment considered
Based on the above design Criteria, the Air Conditioning Load for the Central
Control Room including the DCS panel room and office area is Calculated at 40 TR.

2 x 18 MW CPP
PP 030 M B01 0 1 87
Four numbers Package Air Conditioning Units (PACs) are considered each with a
capacity of 10 TR., for the central Control Room.
Ventilation System Sizing
For ventilation system, the maximum of air quantity is derived from

a) The equipment heat loads and /or
b) Air-change rate as recommended by “Association of Ventilation Engineers”
India.
The type of ventilation system provided for various areas is based on the inside
condition to be maintained, the heat loads, ease of operation and maintenance and
reliability. The wet pressurised ventilation system will be provided in the following areas.
i) Cable spreader room
ii) Switchgear room
iii) Turbine hall
Design basis : Maximum of air quantity derived from
a) Air Changes : 8 per hour for TG Operating Floor
15 for SWGR Room
10 for Cable Spreader Room
Air quantity required for TG Hall: [40000+Exh.From Electrical Rooms]
m3/hr
Air quantity required for SWGR Hall: 45000 m3/hr
Air quantity required for Cable Spreader Room: 35000 m3/hr
Total for electrical rooms : 80000 m3/hr
Based on the above calculations, two Air washers are considered for the STG-1
Bldg Ventilation & two Air Washers are considered for the STG-2 Bldg Ventilation. Each
Air Washer will have a standard size of 35,000 m3/hr each.

2 x 18 MW CPP
PP 030 M B01 0 1 88
This type of units consists of sheet metl enclosure complete with air intate louvers,
Air washer section having wier mesh filter with water spry ;PVC Fill with water spry, drift
eliminators ; fan section;water tank;water circulating Pump etc.
Turbine hall shall be provided with roof mounted exhausters. Roof extractors will
be sized to extract a part of the air delivered by air washers. 7 numbers Roof Exhausters
are considered, with a capacity each of 12000 m3/hr is considered.
Battery Room ventilation
9 Type of ventilation:Negative ventilation

9 Design basis:To maintain maximum allowable levels of
9 Acidic/fumes in the ventilated space as
9 per OSHA/ACGIH standards.
9 Air distribution:Exhaust through fans, intake through
9 door /wallmounted louvers.
9 Equipment:Exhaust fan
9 No. of air changes:20
9 Toilets
9 Type of ventilation:General exhaust
9 Design basis:20 Air changes per hour basis
9 Equipment:Wall mounted exhaust fans
Air Compressor Room
9 Type of ventilation:Dry exhaust ventilation

9 Design basis : 10 air changes per hour
9 Air distribution :Exhaust through fans, intake through wall
openings/louvers.
Equipment : 2 x 60% fans, 7500-m3/hr capacity each.

2 x 18 MW CPP
PP 030 M B01 0 1 89
14. EOT CRANE

14.1.DESCRIPTION
An Electric Overhead Crane is provided for the STG building for maintenance
activities of the Steam Turbine Generator as movement of the components will be required
in both cross wise and longitudinal direction for which a monorail electric hoist will not
serve the purpose.
The design, manufacture, and testing of electric over head travelling crane
mechanical and electrical components shall conform IS 3177-1977. Structural design of
the EOT crane will conform to IS 807-1976.
The crane shall be designed for an estimated life of crane of 20 years with 300 days
per year with operation of 1.5 hours per day of running time, which falls under class-II
operation as per IS 3177.
14.2.EOT CRANE SIZING
The criterion for selecting a crane is based on maximum load and the raising and
lowering heights of assembly / sub assembly being lifted during maintenance work.
The part with the maximum weight for the Steam Turbine Generator is for the
Generator Rotor. The weight of the Generator Rotor is 18 Tonnes. The EOT Crane has
therefore been designed for a capacity of 35T / 5T.
1
Brief details of the EOT crane are as below:
¾ Quantity:1 No.
¾ Location: Indoor
¾ Design according to standard: IS 3177 / IS 807
¾ Duty class : II
¾ Main: 35 Tons
¾ Auxiliary:5 Tons
¾ Crane travelling speed: 10 / 1.0 m/min.

2 x 18 MW CPP
PP 030 M B01 0 1 90
¾ Crab traversing speed:10 / 1 m/min.
¾ Main hoisting speed:1.2 / 0.12 m/min.
¾ Auxiliary hoisting speed:5.0 / 0.5 m/min.
15. FIRE PROTECTION SYSTEM

15.1.PROCESS DESCRIPTION
The fire protection and detection system for the Captive Power plant is provided for
early detection, alarm containment and suppression of fire. The fire protection and
detection system shall be designed generally in line with statutory and insurance
requirement of Tariff Advisory Committee (TAC) of India. The facilities of fire protection
system are designed to fight major fires within the plant. A pressurised hydrant system is
provided for protection of entire plant
It is ensured that adequate firewater storage is available as dead storage in the Raw
/ Firewater reservoir for protection of the installation from fire hazards. 550-m3 storage
capacity has been reserved in the Raw Water Reservoir for Fire Water System
requirements
All the areas in the plant are protected by hydrant system. As per TAC’s Fire
Protection Manual, the risk is categorised under ordinary hazard category and the Fire
Hydrant System shall be designed to meet the same.
The fire water system should be laid in ring mains around all areas to ensure
multidirectional flow. The fire water mains will be buried 1m below the ground and will
be coated and wrapped to take care of soil corrosion. Isolation valves will be provided in
the network to enable isolation of any section of the network without affecting the flow in
the rest.
Fire Water pumps will be provided, as follows for the Fire Protection System.
• Electric motor driven centrifugal pump : 1 Nos.
• Diesel engine driven centrifugal pump : 1 No

2 x 18 MW CPP
PP 030 M B01 0 1 91
The pumps shall be directly coupled. Parts of the pumps like impeller, shaft sleeve,
weaving ring etc. shall be of bronze.
Automatic starting devices should be installed for the fire pumps.
In order to maintain the distribution system under pressure at all times, jockey
pump is proposed to take care of system losses.
Firewater pumps shall be exclusively used for fire fighting purposes only.
15.2.SYSTEM SIZING CALCULATION 1
Considering the guidelines of TAC for Ordinary Hazard,
The number of Hydrants required in the plant is found out to be about 35 For
hydrants below 55, the pump flow rate required is 171 m3/hr.
For HPWS system for Gen. Trafo. Expected Design water flow rate is about 100
3
m /hr.
For MVWS System for Cable Spreader Room in STG Building Expected Design
Flow rate is 210 m3/hr.
As per TAC guideline ;approved Pump capacity nearest to max. flow rate required
for MVWS System is 273 m3/hr.
In view of above Fire Water Pump with flow rate of 273 m3/hr will be provided for
Hydrant system and requirement for HVWS & MVWS system will tapped from nearby
hydrant Mains. Diesel Engine Driven pump same capacity will be provided as standby for
motor driven pump..
Considering TAC requirements, the storage requirement is considered as 2 hrs. for

Hydrant system & 40 min. storage for HPWS system ,550 m3 capacity will be reserved in
the Raw Water Reservoir for Fire Fighting Purposes.

2 x 18 MW CPP
PP 030 M B01 0 1 92
15.3.PUMP SIZING
♦ Fire Water Pumps
Quantity / Standby 1 A/C driven Discharge Head at Pump 88

/ 1 Diesel Outlet (mLC) as per TAC
Engine
driven
Pumping Temp (0C) 33 Casing MOC CI
Capacity (m3/hr) 273 Impeller MOC Bronze
♦ Jockey Pump
Quantity / Operating / 1/0/0 Discharge Head at Pump 88

Standby Outlet (mLC)
Pumping Temp (0C) 33 Casing MOC CI
Capacity (m3/hr) 8.0 Impeller MOC CI
15.3.1. LINE SIZING
The main Fire Water main has been sized at 200-mm NB Hydrant Mains will be
laid in rings and Line size will be as per TAC guidelines.
16. PIPING SYSTEM

The piping for the power plant is grouped into power cycle piping, low-pressure
utility piping and cooling water piping.
The technical and design features of each group are elaborated below.
16.1.POWER CYCLE PIPING
Power cycle piping consists of the following major lines:
Main steam piping line at 89 Kg/cm2 (a), 515°C (Operating Parameters) from
each Boiler connected to a common header. Steam piping to the Steam
Turbine will be tapped from this main steam header.
Extraction steam line from the turbine at 21.75 Kg/cm2 (a) for supply to HP
Heater.
Extraction steam line at 5.74 Kg/cm2 (a) to deaerator.

2 x 18 MW CPP
PP 030 M B01 0 1 93
Extraction steam pressure to LP heater at 2.0 Kg/cm2 (a).

Boiler feed water pump suction piping.
Boiler feed water pump discharge piping.
Boiler feed water pump recirculation piping.
Condensate extraction pump suction piping.
Condensate extraction pump discharge piping.
Boiler blowdown, all drains and vents
Spray water lines.
16.2.LOW PRESSURE UTILITY PIPING
The low-pressure utility piping will mainly cover the following services:
DM Makeup water for Power cycle.

Makeup water for cooling tower.
Cooling tower blowdown.
Raw water
Potable water
Service water
Instrument air
Service air
Effluent
Vents and drains
Fire fighting system
16.3.COOLING WATER PIPING
This piping consists of the following:

Auxiliary cooling water system
16.4.DESIGN BASIS FOR PIPING
In the design of all pipe lines, the sizing of lines will be based on the maximum
flow through the line and the allowable pressure drop through the lines including those of
control valves, flow elements, strainers, etc., so as to maintain the required pressure at
2 x 18 MW CPP
PP 030 M B01 0 1 94
various consumption points. In all the cases, the velocity of flow in the lines will be
restricted to a maximum value as per the table below. The thickness calculations for IBR
piping will be based on ANSI B31.1 or IBR whichever is more stringent for the design
pressure, and the allowable stress shall be as per ANSI B31.1 for the selected pipe material
at the design temperature.
The thickness calculation for non-IBR pipes shall be as per ANSI B31.1 or IS 1239 /
IS 3589 for the design pressure and the allowable stress value for the selected pipe material at
the design temperature. Corrosion allowance (0.75 mm for steam piping as per IBR) will be
added in addition to tolerance on pipe thickness. Whenever pipe bends are used for larger
wall thickness pipes, the wall thinning factor as per Power Piping design standards ANSI
B31.1 will be used and the thickness of pipe bends will be suitably increased.
The Material of Construction for various Piping, Valves & Fittings shall be as per
attached document, “Piping Material Specification Summary”.
1. Steam lines
Average velocity in metres / second
Below 50 to 150 200 mm NB
50 mm mm NB & up
NB
1. Saturated steam at 1.1 to 7.0 ksc (g) 15-20 20-35 25-45
2. Saturated steam over 7.0 ksc (g) 15-25 20-35 30-50
3. Superheated steam at 0 to 7.0 ksc (g) 20-30 25-40 30-50
4. Superheated steam at 7.1 to 35 ksc(g) 20-35 30-45 30-55
Superheated steam at 35.1 to 70 ksc
5. 20-35 30-50 40-60
(g)
6. Superheated steam over 70 ksc (g) 20-35
7. Exhaust steam line from turbine to 20 For all line sizes
atmosphere
8. Vacuum lines 60 For all line sizes
2. Water lines
Velocity (m/s)
Feedwater suction lines 0.6 to 1.0

2 x 18 MW CPP
PP 030 M B01 0 1 95
Feedwater discharge lines 1.0 to 4.0
Auxiliary cooling water suction 0.6 to 1.5
Auxiliary cooling water delivery lines 0.9 to 2.2
Condensate delivery lines 0.9 to 2.2
Condensate suction lines 0.4 to 0.7
Service water / potable water 0.9 to 2.2
Cooling water sump blowdown 0.3 to 0.6
Rubber lined piping in DM plant area 0.9 to 2.0
3. Air Lines
Pipe Size below 50mm 15-20
Pipe Size 50 to 150mm 15-30
Pipe Size 20mm & Up 25-35
16.5.MAIN STEAM PIPING
The design conditions for the main HP Steam line from each Boiler shall be 95
2
Kg/cm (a). The pipe shall be designed for the MCR conditions of the Boilers. The material
of piping will be alloy steel conforming to ASTM A 335 Gr. P22.
Main steam lines from both Boilers will be connected to the main steam header. The
pipeline shall be designed as per IBR.
From boiler superheater outlet to steam turbine inlet, line sizes will be adequate so
that pressure drop shall not exceed 2 kg/cm2.

2 x 18 MW CPP
PP 030 M B01 0 1 96
16.6.OTHER STEAM PIPELINES
The material for these lines (LP steam, Aux. Steam shall be carbon steel conforming
to ASTM A106 Gr. B. Steam velocity shall be maintained in all these pipe lines as indicated
in the above table.
16.7.BOILER FEEDWATER PIPING
16.7.1. BOILER FEED WATER SUCTION LINES
The piping material shall be carbon steel conforming to ASTM A 106 Gr.B. For
sizing of the lines, the velocity of flow will be maintained between 0.6 and
1.0 m/sec for BFP Suction Piping.
16.7.2. BOILER FEEDWATER RECIRCULATION PIPING
Separate recirculation line for each boiler feed pump will be provided from the non
return cum modulating recirculation valves, with necessary isolation valves and pressure break
down orifices and will be connected to the deaerator. The material shall conform to ASTM A
106 Gr. B.
16.7.3. BOILER BLOW DOWN, VENTS, DRAINS, ETC.
Blow down piping will connect the drains from boiler drums, superheaters, bottom
ring headers, etc., with the blow down tank. Some high pressure drains from different piping
and equipment are also connected to flash tank while others are quenched and let off to the
plant drains. The material shall be carbon steel confirming to ASTM A106 Gr. B.
16.8.CONDENSATE PIPING
The piping shall be sized for the maximum flow to the condenser under various
modes of operation. The material shall be carbon steel confirming to ASTM A106 Gr. B.
16.9.PIPING FOR RAW WATER, COOLING WATER
The material of piping will be carbon steel as per IS:1239 (Class-Heavy) / IS: 3589.
The design pressure of the piping will be the shut-off heads of the respective pumps.

2 x 18 MW CPP
PP 030 M B01 0 1 97
16.10.AIR PIPE LINE
The material for air pipeline will be galvanised carbon steel (IS 1239- Class H) pipe.
Tappings will be made from respective headers at the nearest point. Air lines shall be
provided with globe / ball valves.
16.11.DM WATER PIPE LINE
The DM water pipe from the DM plant to the DM water storage tank and from the DM
water storage tank would be routed through suitably sized pipeline. Pipe material within DM
plant shall be IS 1239 / IS 1239 (rubber lined)t. The DM water line and valves beyond DM
Plant vendor battery limit if suitably dosed for pH correction shall be A 106 Gr. B. In case pH
correction of the water is not done the pipeline shall be of SS 304.
16.12.EFFLUENT
The material will be IS 1239 Class H.
16.13.SERVICE AND POTABLE WATER PIPE LINE
The service and potable water pipe lines shall be routed separately throughout the
power plant. The material of service water shall be carbon steel conforming to IS 1239 Class
H and potable water shall be of carbon steel conforming to IS 1239 GI.
16.14.AUXILIARY COOLING WATER PIPING
The auxiliary cooling water header shall be buried. From the header branch lines for
lube oil coolers of STG, Generator air coolers of STG and for other utilities will be tapped.
The return piping shall be routed to cooling tower inlet. The material of construction shall be
IS 1239 / IS 3589.
16.15.FIREWATER PIPING
Firewater piping will be routed from the fire pump house of the power plant. It will be
routed around the turbine building, Boiler area, electrical bay, transformer yard, coal area, etc.

2 x 18 MW CPP
PP 030 M B01 0 1 98
The fire water piping will be buried at 1 m below the ground and the external hydrant
valves will be provided above ground. For above ground pipes of size 150 NB and above the
material will be carbon steel as per IS: 3589 and for pipes of sizes below 150 NB the material
will be IS: 1239 medium grade as recommended by TAC.
16.16.VALVES
The design, material, construction, manufacture, inspection and testing of valves

and specialities will comply with all currently applicable standards, regulations and codes.
All drain and vent connections for 40 Kg/cm2(a) rating will be made up of two (2)
valves in series, both of isolating type.
All valves and specialities will be located so that they are readily accessible for
both operation and maintenance. Wherever necessary, the valve spindles will be extended
and an approved type of pedestal handwheel will be provided at the next higher floor level
or a necessary platform will be provided.
Motor operated valves will be provided with hand- operated device for operating
the valves during power failure. All motor-operated valves shall have open and close limit
switches, integral starters and push-buttons.
Gear operation for valves will be provided for the sizes as indicated in the
following table:
Valve Type Class Sizes
Gate and Globe up to 300# 350NB and larger

600# - 900# 150 NB and larger
1500# - 2500# 100 NB and larger
Ball upto 300# 150 NB and larger

600# - 1500# 80 NB and larger
Plug upto 150# 100 NB and larger

300# to 1500# 80 NB and larger
Butterfly Valves 150# 150 NB and larger

2 x 18 MW CPP
PP 030 M B01 0 1 99
Effort to operate valves will not exceed 20 kg at hand wheel periphery/lever end.
Hand wheel diameter will not exceed 700 mm and lever length 500 mm.
For gate valves, bypass arrangement (separate or integral) will generally be

provided for following sizes and whenever the line pressure exceeds 40-ksc (a).
Rating Size
900# 200 NB and larger
The bypass valve shall be a globe valve and the bypass arrangement to main valve
will not be screwed.
For storage tanks, isolation valves will be provided directly on the tank nozzle.
All HP steam line valves of 300# and above shall be welded.

Formatted: Bullets and Numbering
16.16.1.INSULATION
All piping systems having working temperature equal to or more than 60 °C will be
normally insulated for conserving enthalpy and for personnel protection.
The insulating material is selected suitably based on the working temperature of the
pipe. It is essential that the material is free from shots, chlorides, oil, Sulphur and other
impurities and retains its density and thermal conductivity over a reasonably long period.
Insulation thickness will be so selected that the temperature of its outside jacket
remains 60°C, since it is expected that such temperature does not produce burns on human
skin within a contact period of 3 seconds. The wind velocity values considered for
calculating insulation thickness shall be 3 m/sec for indoor and outdoor installations at an
ambient temperature of 38 oC.
16.16.2.PIPE SUPPORTS AND HANGERS
Pipe supports shall be designed according to the layout requirements. Wherever

the load variation is limited, variable spring hangers and constant spring hangers are used.

2 x 18 MW CPP
PP 030 M B01 0 1 100
In other places, other type of supports like rod hangers, clamps, saddle supports etc. are
used.
16.16.2.1. Constant Spring Hangers
The deviation in supporting effect shall be limited to ± 8% for constant spring

hangers throughout the total travel.
16.16.2.2. Variable Spring Hangers
The deviation in supporting effect shall be limited to ± 25% for variable spring
support system.
16.16.2.3. Rod Hangers
Rod hangers are used in those cases where lateral movement is allowable.
16.16.2.4. Pipe Clamps and Shoe / Saddle supports
This shall be used in those cases where restraint supports are used. Minimum
thickness of pipe clamps shall be 5-mm.
16.16.2.5. Materials of Construction
Spring shall be of EN42 / EN45 / EN45A / EN60.

Plates and flats shall be of IS 2062 or equivalent. However, material of alloy
steel shall be of equivalent to A 335 P22.
Hanger rods shall be of IS 2062 or equivalent.
Spring casings shall be of ERW pipes of IS 3589 / IS 1239.
Turnbuckles shall be of SA 105 or equivalent.
16.17.GENERAL GUIDELINES FOR PIPING
Piping layout is dictated by the relative locations of connecting equipment and

the requirements of stress analysis.
Adequate number of drain and vents shall be provided as per the system /
layout requirements.

2 x 18 MW CPP
PP 030 M B01 0 1 101
Suitable clearances shall be provided with respect to other equipment,

structures, pipe to pipe distances and for ease of access and maintenance.
Valves shall be located and oriented such a way that these are easily accessible
for operation and maintenance.
While providing openings in floor/walls for pipe crossing due care shall be
taken for the pipe thermal movement and insulation thickness.
17. ENVIRONMENTAL CONSIDERATION

Both gaseous emission & liquid effluent are discharged from the plant taking into
consideration, the environmental norms & emission standards.
17.1.GASEOUS EMISSION
Being a coal fired plant, the gaseous emission is from the chimney exhaust.
From gaseous pollution point of view, the worst case fuel combination is 70 : 30
pet coke : imported coal. To reduce the SO2 emission, limestone dosing is done in bed for
Sulphur capture. Particulate emission is taken care by providing electrostatic precipitator
(ESP). ESP will be designe for 50 mg/nm3 with all fields in operation.
93 meters high chimney is provided as per the Pollution board norms to restrict the
ground level concentrations within acceptable limits. The chimney height is calculated
based on 70% petcoke + 30% imported coal firing at 100% MCR condition.
Chimney Height Calculation
Fuel consumption for 2 boilers 2 x 8202 = 16404

kg/hr
Sulphur in fuel (mixture of 4.69%

70% petcoke & 30% imported
coal)
Total Sulphur 769.34 kg/hr
Total SOx generation 1538.7 kg/hr

2 x 18 MW CPP
PP 030 M B01 0 1 102
SOx abetment 65%
Total SOx at stack inlet 538.5 kg/hr
Stack height 92.3 m
Stack height selected 93 m
Note: Chimney height is calculated based on performance fuel
17.2.LIQUID EFFLUENT
Liquid effluent from the CPP is generated from the following sources.
¾ Cooling Tower Blow-down
¾ Side stream filter back wash
¾ DM Plant Reject
The system design (cycle of concentration) is done such that the effluent TDS does not
exceed 2100 ppm. However, this figure may increase in case there is an increase in inlet
Raw Water TDS. In that case, higher blow-down need to be done from Cooling tower to
maintain designed effluent TDS.
An effluent pit with 2x100% effluent discharge pump will be provided. Total quantity
effluent generated in the plant is as follows.
Formatted: Not Highlight
a) Cooling tower Blow down 4.5 m3/hr Formatted: Not Highlight
b) Side stream filter back- 0.54 Generated once in a day i.e 13 m3/day
wash m3/hr
c) From DM water generation 0.58 Generated once in a day i.e 14 m3/day Formatted: Not Highlight
plant m3/hr Formatted: Not Highlight

d) From Boiler blow down 2.4 m3/hr Formatted: Not Highlight
(considering 1.5%) Deleted: 28
e) From HRCC 0.42 Led to sludge pit, to be disposed by
m3/hr sludge pumps.
2 x 18 MW CPP
PP 030 M B01 0 1 103

Total 8.44
m3/hr
Effluent Pit
1
The effluent pit is sized with the following basis.

a) One day’s DMF back wash 6 m3 Formatted: Not Highlight
volume
b) One day’s DM water 8 m3 Formatted: Not Highlight
generation Plant reject
c) 8 hrs storage for RO system 14.67 m3

reject
d) 8 hrs storage for CT blow- 36 m3 Formatted: Not Highlight
down Formatted: Not Highlight
e) 8 hrs for Boiler blowdown 19.2 m3
f) One day’s SSF backwash 13 Formatted: Not Highlight
waste
Effective volume for effluent 96.87 m3 Selected effluent pit size = 115m3 Formatted: Not Highlight
pit
Effluent Disposal
An effort is made to use the plant effluent for dust suppression requirement within the plant,
viz., for :
1. Meeting ash conditioner water requirement.
2. Spray water requirement near the truck tippler area
Two numbers (1working & 1 stand by ) effluent transfer pumps shall be provided for
evacuating effluent. The plant effluent water will be used for meeting the dust suppression
water requirement for ash conditioners and dust suppression at the grizzly hopper. The
capacity has been worked out based simultaneous water requirement for 1no. bed ash
2 x 18 MW CPP
PP 030 M B01 0 1 104
conditioner and 1 no. fly ash conditioner working and the head is selected such that water at
2.5bar is available at the ash conditioners.
18. REFERENCE DRAWINGS & DOCUMENTS

This DBR is to be read in conjunction with the following drawings & documents.
♦Plot Plan drawing number : PP 030 M 201 1 Rev. 1
♦Piping material spec summary enclosed (Annexure 1)

2 x 18 MW CPP
PP 030 M B01 0 1 105
Annexure 1

COGEN DIVISION
Project Document Title Doc. No.
2 x 18 MW CPP
Design Basis Report (Mechanical) PP 030 M B01 0
JK Cement Ltd, Sirohi, Rajasthan Deleted: Dwarkesh Energy
Deleted: Ltd
Deleted: 2 x 18 MW CPP¶
Material Specification Summary Annexure 1 Madras Cements Limited, Alathiyur¶
Deleted: PP 019 M B01 0
Design Pipe Inserted: Ltd, Sirohi, Rajasthan
Sr Conditions Size Flange Flange Gasket Fittings
Service Pipe MOC
no Temp Pre mm- MOC Rating MOC MOC
0
C Kg/cm2 NB B
below A182
SS 304
89 Kg/cm2 (a) 50 F22 Deleted: 515
1. 520 95.0 A335 P22 A 182 F22 1500# Spiral
Pressure Steam 50 & A234
wound
above WP22
below A182
SS 304
21.8 Kg/cm2 (a) 50 F11
2. 360 24 A106 Gr. B A 105 300# Spiral
Pressure Steam 50 & A234
wound
above WP11
4.8 Kg/cm2 (a). below A182

330 18 SS 304
Pressure steam 50 A106 / A53 F11
3. A105 300# Spiral
Gr. B
wound
1.12 Kg/cm2 (a). 50 & A234
220 6 A
Pressure steam above WP11
below
A105
50 SS 304
Boiler feed A106 / A53
4. 230 115 50 & A105 900# Spiral A234
water Gr. B A
above wound WPB
Sr Design Pipe Flange Flange Gasket Fittings

Service Pipe MOC
no Conditions Size MOC Rating MOC MOC
COGEN DIVISION
Project Document Title Doc. No.
2 x 18 MW CPP
Madras Cement Limited,Alathiyur Design Basis Report (Mechanical) PP 019 M B01 0
Temp Pre mm-

0
C Kg/cm2 NB B
below
A105
50 A106 / A53
5. Condensate 95 12 A105 150# CAF
50 & Gr. B A234
A
above WPB
below IS 1239
50 IS 1239 Part II
6. Compressed Air 60 10 A105 150# CAF
50 - Part-1 GI A234
A
150 WPB
below IS 1239
Potable water A105 A105
150 Part-I GI
7. 40 5.0 150# CAF
200 & IS: 2062
Service water IS3589 IS3589 A
above Gr. A
below IS 1239 A105
A105
Cooling water, 150 Part-I AWWA
8. 50 5.0 Std
CAF
Raw Water 200 & IS:2062
IS3589 IS3589 A
above Gr. A
below A182 F
50 A312 304
9. DM water 40 12 A182 F304 150# CAF
50 & TP304 A403
A
above WP304

DBR 2x18MW

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OC No.

DESIGN BASIS REPORT

Rev Date Description of Revisions Status

OWNER JK CEMENT LTD LIMITED

PROJECT 2 x 18 MW COAL BASED CAPTIVE POWER PLANT

Format No.:CGN-E-F-03, Sht 1, Rev 1 dt. 02/Mar/2001

2. UNITS OF MEASUREMENT & ABBREVIATIONS...............................................................................5

4. POWER PLANT CONFIGURATION........................................................................................................8

Format No.: CGN-E-F-03, Sht 2, Rev 1 dt. 02/Mar/2001

8.2. FEED WATER SYSTEM ............................................................................................................................49

Format No.: CGN-E-F-03, Sht 2, Rev 1 dt. 02/Mar/2001

17.1. GASEOUS EMISSION ..........................................................................................................................101

Format No.: CGN-E-F-03, Sht 2, Rev 1 dt. 02/Mar/2001

2. UNITS OF MEASUREMENT & ABBREVIATIONS

Deg.C Degree Celsius

ACW Auxiliary Cooling Water System

Format No.: CGN-E-F-03, Sht 2, Rev 1 dt. 02/Mar/2001

CHP Coal Handling Plant

3. CODES & STANDARDS

• Indian Standards (IS)

• International Electrotechnique Commission (IEC)

• American Society of Mechanical Engineers (ASME)

• American Society of Testing and Materials (ASTM)

Format No.: CGN-E-F-03, Sht 2, Rev 1 dt. 02/Mar/2001

• American Welding Society (AWS)

• American Water Works Association (AWWA)

• American National Standard Institute (ANSI)

• Heat Exchanger Institute (HEI)

• Manufacturer’s Standardisation Society (MSS)

• Hydraulic Institute (HI)

• Japanese Industrial Standards (JIS)

• Tariff Advisory Committee of India (TAC)

• National Fire Protection Association (NFPA)

• Occupational Safety and Health Administration (OSHA)

• Steel Structures Painting Council (SSPC)

• Tubular Exchanger Manufacturer & Association (TEMA)

• Indian Boiler Regulation (IBR) Act

• American Petroleum Institute (API) codes

• Indian Explosives Act

• Environment Protection Agency (EPA) codes

• Oil Industry Safety Directorate (OISD)

Format No.: CGN-E-F-03, Sht 2, Rev 1 dt. 02/Mar/2001

4. POWER PLANT CONFIGURATION

The Captive power plant consists of the following;

(b) 100% Imported coal

(c ) 100% Indian coal

Format No.: CGN-E-F-03, Sht 2, Rev 1 dt. 02/Mar/2001

The boilers will be connected to a common RCC chimney, 93m height..

4.2. PLANT STARTUP

For details refer to Electrical and C&I design basis report.

4.3. SITE CONDITIONS

•Site Elevation : 372M above MSL

4.3.2. AMBIENT CONDITIONS

•Maximum Ambient Temperature : 46°C

•Design ambient for electrical equipment : 50°C

•Design Relative Humidity : 60%

•Average rain fall per annum : 484 mm / year

•Basic wind speed : 47 m/s

•Design wet bulb temperature : 28 °C

4.3.3. SEISMIC DATA

4.3.4. SOIL DATA

4.3.5. POWER SUPPLY

• For AC motors above 180 kW : 6600 V (±10%), 3 phase, 50 Hz ±5% earthed